Manual Alternator PDF

2327 en – 11.
2011 / o
ALTERNATOR
Service & Operating Manual
LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en – 11.2011 / o
ALTERNATORS
TABLE OF CONTENTS
2.3.3 Maintenance of antifriction bearings

1. GENERAL INFORMATION a) General points
b) Lubricant
c) Cleaning bearings
1.1 INTRODUCTION 2.3.4 Servicing the antifriction bearings
1.1.0 General points a) General points
1.1.1 Safety notes b) Removing the bearings
1.1.2 Conditions of use c) Bearing reassembly
a) Generalities 2.3.5 Antifriction bearing protection devices
b) Vibratory analysis 2.3.9 Antifriction bearing installation drawing
1.2 GENERAL DESCRIPTION 2.4 SLEEVE BEARINGS (Plain)

1.2.1 Generator 2.4.0 Description of horizontal Sleeve bearings
1.2.2 Excitation system a) Physical description
b) Operating description of Self-lubricating
2. DESCRIPTION OF SUB-ASSEMBLIES bearing
c) Operating description of Oil circulation bearing
2.4.1 Electrical insulation of Sleeve bearings
2.1 STATOR a) Illustration diagram of the insulating film
2.1.1 Electric machine armature b) Insulation check
a) Mechanical description 2.4.2 Storage of Sleeve bearings machine
2.1.2 Excitation field winding a) General points
2.1.3 Stator protection b) Short term storage
a) Heating resistor c) Long term storage
b) Stator winding temperature sensor 2.4.3 Oil circulation installation
c) Stator air sensor 2.4.4 Start-up of Sleeve bearings
d) Stator vibration sensor a) General check before start up
b) Self-lubricating bearings start up data
c) Water cooled bearing (type EFW..) start up
2.2 ROTOR
data
2.2.1 Revolving field-coil
d) Oil circulation bearing with non-accurate oil
2.2.2 Excitation armature
flow (+0% ; -40%)
2.2.3 Fan (machines: IC 0 A1)
e) Oil circulation bearing with accurate oil flow
2.2.4 Rotating diode bridge
(+5% ; -10%)
a) General points
f) Inspection of Sleeve bearings at the end of
b) Tightening torque for the rotating diode
start-up
fastening screws
2.4.5 Maintenance of Sleeve bearings
c) Rotating rectifier test
a) Verification of oil-level
2.2.5 Balancing
b) Temperature verification
2.2.6 Rotor vibration sensor
c) Oil draining
d) Pressure measurement of a Sleeve bearing
2.3 ANTI FRICTION-BEARINGS housing
(rolling bearing) e) Oil for sleeve bearing
2.3.0 Description of antifriction bearings f) Oil sump capacity
2.3.1 Start-up of antifriction bearings g) Sealing Compound
2.3.2 Storage of machine with anti friction
bearings
3
ALTERNATORS
2.4.6 Dismantling
a) Tools and equipment
b) Lifting equipment 2.7 COOLER
c) Dismantling of the shaft seal type 10 (outboard 2.7.0 Description of the cooler
side) a) General points
d) Dismantling of the shaft seal type 20 (outboard b) Description of AIR-AIR coolers
side) c) Description of AIR-WATER DOUBLE TUBE
e) Dismantling of the top half of the housing EXCHANGER
f) Removal of the top half of the shell d) Description of AIR / WATER SINGLE TUBE
g) Dismantling of the loose oil ring EXCHANGER
h) Dismantling the machine side shaft seal 2.7.1 Water Cooler operating condition
i) Removal of the bottom half of the shell a) Water Cooler installation
j) Dismantling of the machine seal b) "Standard" operation with water
2.4.7 Cleaning and checking c) "Emergency" operation without water
a) Cleaning 2.7.2 Start-up of the water cooler
b) Wear checking a) General points
c) Insulation checking (only for insulated bearing) 2.7.3 Maintenance of the water-cooler
2.4.8 Assembly of the Bearing a) General points
a) Fitting in the bottom half of the shell b) Cleaning
b) Assembly of the shaft seal machine-side c) Leak detection for a double-tube exchanger
c) Installation of the loose oil ring 2.7.4 Servicing the water-cooler
d) Fitting in the top half of the shell a) Cooler removal
e) Closing of the bearing b) Cooler re-assembly
f) Assembly of the type 10 Outboard Side Seals 2.7.5 Cooler protection devices
g) Assembly of the type 20 Outboard Side Seals a) Leak detection (float system)
h) Assembly of the RD-thrust pads ; bearing type b) Water temperature sensor
E...A c) Water filtering
2.4.9 Oil-leakage trouble-shooting
a) Self-lubricating bearing
b) Oil circulation bearing 2.8 AIR FILTERS
2.4.10 Sleeve bearing protection devices 2.8.0 General
a) Sight-level glass 2.8.1 Cleaning
b) Oil thermometer a) Air filter cleaning period
c) Thermostat or sensor b) Air filter cleaning procedure
d) Pre lub pump
e) Oil filtering and pollution 2.18 TERMINAL BOX
2.18.0 Description
2.6 OIL CIRCULATION LUBRICATING UNIT 2.18.1 Electric panel
2.6.0 General points a) Compounding panel ( if compound regulator)
2.6.1 Oil circulation by gravity return b) Booster plate ( if shunt regulator)
a) General points 2.18.2 Automatic voltage regulator
b) Supply line 2.18.3 Electrical contact tightening
c) gravity oil return
2.6.2 Oil cooling unit Air/Oil exchanger 2.19 PROTECTION DEVICES
2.6.3 Oil cooling unit Water/Oil exchanger 2.19.1 Stator protection devices
2.19.2 Bearing protection devices
2.19.3 Cooler protection devices
2.20 NAMEPLATES
2.20.1 Main nameplate
2.20.2 Lubrication nameplate
2.20.3 Rotation direction nameplate
4
ALTERNATORS
3. VOLTAGE REGULATOR AND EXTERNAL 5. START-UP

AUXILIARIES
5.0 START-UP SEQUENCE
4. INSTALLATION 5.0.1 Static checks
5.0.2 Rotating checks
a) Rotating checks not excited
4.1 TRANSPORT AND STORAGE b) Rotating checks at no load excited
4.1.1 Transport c) Generator and site safeties
4.1.2 Storage warehouse d) Rotating checks at full load
4.1.3 Maritime packing 5.0.3 Generator Start Up check list
4.1.4 Unpacking and installation
4.1.5 Storage measures of a site machine
5.1 ELECTRICAL START-UP INSPECTION
5.1.0 General points
4.2 INSTALLATION OF THE MACHINE 5.1.1 Windings Insulation
4.2.1 Fitting the coupling (double-bearing 5.1.2 Electrical connections
machine only) 5.1.3 Parallel operation
4.2.2 Fitting the stator a) Definition of parallel operation
b) Possibility of parallel operation
c) Parallel coupling
4.3 ELECTRIC MACHINE ALIGNMENT
4.3.1 Various alignment characteristics
a) General points 5.2 MECHANICAL START-UP INSPECTION
b) Axis height Thermal elevation 5.2.0 General points
c) Sleeve bearing shaft elevation a) Alignment; fixing; prime mover
d) Antifriction bearing shaft elevation b) Cooling
4.3.2 Two bearings machine alignment c) Lubrication
a) machines without axial end play (standard) 5.2.1 Vibrations
b) machines with axial end play
4.3.3 Single bearing machine alignment 6. PREVENTIVE MAINTENANCE
a) General points
b) Single bearing machine
4.3.4 Alignment procedure 6.1 MAINTENANCE SCHEDULE
a) Checking "Double concentricity" alignment
method
6.2 MECHANICAL MAINTENANCE
6.2.1 Air gap check
4.4 ELECTRICAL CONNECTIONS a) General points
4.4.0 General points b) Double bearing machine
4.4.1 Phase-sequence c) Single bearing machine
a) standard machine.IEC 34-8 6.2.2 Bolts tightening
b) if wanted, NEMA. 6.2.3 Cleanliness
4.4.2 Insulating distances
4.4.3 Added products in the terminal box 6.3 ELECTRICAL MAINTENANCE
6.3.1 Measuring instruments
a) Instruments used
b) Identification of ohmmeter polarity
6.3.2 Insulation check of the winding
a) General
b) Armature insulation measure
c) Field insulation measurement
d) Exciter insulation measurement
e) Polarisation index
5
ALTERNATORS
7. SERVICING
7.1 GENERAL SERVICING
7.2 TROUBLE SHOOTING

7.2.1 Regulator trouble-shooting procedure
7.3 ELECTRICAL TESTS

7.3.1 Stator winding test
7.3.2 Rotor winding test
7.3.3 Excitation armature winding test
7.3.4 Excitation field winding test
7.3.5 Rotating diode bridge test
7.3.6 Electric panel test
7.4 CLEANING THE WINDINGS

7.4.1 Coil-cleaning product
a) general
b) Cleaning products
7.4.2 Cleaning the stator, rotor, excitation and
diodes
a) using specific chemical product
b) Rinsing using soft water
7.5 DRYING THE WINDING

7.5.1 Drying method
a) General points
b) Drying generator stop
c) Drying generator in rotation
7.6 RE-VARNISHING
10. FOLDOUT
6
ALTERNATORS
1. GENERAL INFORMATION 1.1.2 Conditions of use

a) Generalities
1.1 INTRODUCTION A machine must only be installed, operated, by qualified
and trained persons.
1.1.0 General points Any technical engineer operating, maintaining this machine
This manual provides installation, operating and must be allowed to practice in regard with local working
maintenance instructions for synchronous machines. It laws (eg: to be certified to operate on high voltage
devices…)
also describes the basic construction of these machines.
This manual is general ; it applies to an entire group of A machine can only be operated for the duty foreseen by
synchronous generators. Additionally, in order to make its original tender.
information-finding easier, Section 1, "Characteristics and The main data of this machine are summarized in "Section
Performance", has been included, describing the machine 1" of this manual
completely (type of construction, type of bearing, Any operating condition other than those specified by the
protection index, and so forth...); this will enable you to original tender must receive a Leroy Somer agreement
determine exactly the chapters which apply to your
Any modification of the machine structure must receive a
machine.
Leroy Somer agreement
This synchronous machine has been designed for a
maximum length of service. To achieve this, it is necessary b) Vibratory analysis
to pay special attention to the chapter concerning the It is the responsibility of the gen set manufacturer to
periodic maintenance schedule for the machines. ensure that the different assembled system will be
vibratory compatible.(ISO 8528-9 and BS5000-3)
1.1.1 Safety notes It is the responsibility of the gen set manufacturer to
ensure that the shaft line torsional analysis has been done
The warnings "DANGER, CAUTION, NOTE" are used to
and accepted by the different parties (ISO 3046)
draw the user’s attention to different points:
CAUTION :
DANGER :
EXCEEDING THE VIBRATORY LEVEL ALLOWED BY
THIS WARNING IS USED WHEN AN OPERATION,
THE STANDARD ISO 8528-9 & BS5000-3 MAY CREATE
PROCEDURE, OR USE MAY CAUSE PERSONAL
HEAVY DAMAGES (BEARING DAMAGE, STRUCURE
INJURY OR LOSS OF LIFE
CRACKS …).
EXCEEDING THE TORSIONAL VIBRATORY LEVEL OF
CAUTION : THE SHAFT LINE (ex: ABS, LLOYD …) MAY CREATE
THIS WARNING IS USED WHEN AN OPERATION, HEAVY DAMAGES (CRANKSHAFT FAILURE ,
PROCEDURE, OR USE MAY CAUSE DAMAGE TO OR GENERATOR SHAFT FAILURE, …)
DESTRUCTION OF EQUIPMENT
Refer to chapter 2.1.3 for further information about the
NOTE : accepted vibration level of the standard ISO 8528-9 and
This warning is used when an operation, procedure, or BS5000-3
delicate installation requires clarification.
7
ALTERNATORS
1.2 GENERAL DESCRIPTION
1.2.1 Generator
The synchronous generator is an alternating-current
machine, without rings or brushes. The machine is cooled
by the flow of air through the machine.
For a better comprehension, use the drawings of chapter
10.
1.2.2 Excitation system

The excitation system is mounted on the side opposite the
coupling.
The excitation system comprises two assemblies:
The excitation armature, generating a three-phase current,
coupled with the three-phase rectifier bridge (comprised of
six diodes) supplies the excitation current to the generator
revolving field. The excitation armature and the rectifier
bridge are mounted on the synchronous generator rotor
shaft and are interconnected electrically with the revolving
field of the machine.
The excitation field winding (stator) is supplied by the
control (in direct current)
5 1
3
4 2
1- Excitation field winding

2- Excitation armature
3- Rotating diode bridge
4- Revolving field
5- Machine stator
8
ALTERNATORS
To improve the machine protection the alarm set point may
2. DESCRIPTION OF SUB-ASSEMBLIES be reduced following effective site information:
Alarm temperature (*) = Highest recorded temp + 10°K
Trip temperature (*) = Alarm temperature + 5 °K
2.1 STATOR (*) do not pass over the values of the previous chart.
(*)Highest recorded temp: Temperature measured at
2.1.1 Electric machine armature the site in the worst temperature condition at the stator
temperature sensor
a) Mechanical description
The machine stator comprises low-loss steel laminations, E.g. : a class B machine reached 110°C during a facto ry
assembled under pressure. The steel laminations are heat run test. Set the alarm temperature to 120°C in stead
blocked axially by a welded ring. The stator coils are of 130°C as indicated in the previous chart. Set the
inserted and blocked in the slots, then impregnated with emergency shutdown to 115°C instead of 135°C as
varnish, and polymerised to ensure maximum resistance to indicated in the previous chart.
mould, excellent dielectric rigidity and perfect mechanical
linking. c) Stator air sensor
As an option an RTD or thermostat can measure the stator
air inlet temperature (cold air)
2.1.2 Excitation field winding
The excitation field winding comprises a solid element and Stator air inlet temperature; Alarm points and shutdown:
a winding. • alarm Nominal air inlet stator + 5 K
• shutdown 80°C
The excitation is flanged on the rear end shield of the
machine. Stator air outlet temperature; Alarm points and shutdown:
• alarm Nominal air inlet stator + 35K
The winding is made of enamelled copper wires. • shutdown Nominal air inlet stator + 40K
NOTE :
2.1.3 Stator protection For an open drip proof machine the nominal air
temperature entering the stator corresponds to the ambiant
a) Heating resistor
temperature
The heating element avoids internal condensation during Inhibit the stator air sensor safety "alarm" for few seconds
the shutdown periods. It is connected to the main terminal during the machine start up;
box strip. The heating resistor is switched on as soon as
the machine is shut down. It is located at the back end of NOTE:
the machine. For a water cooled machine (CACW) the nominal air
entering the stator may be approximated as following:
The electrical characteristics are provided in Section 1 Tair entering stator = Twater entering cooler + 15°K
"Technical Characteristics".
b) Stator winding temperature sensor

The temperature sensors are located in the active part of
the stack. They are located in the zone assumed to be the
hottest part of the machine. The sensors are connected to
a terminal box.
Depending on the temperature rise of the machine, the
temperature of the sensors should not exceed a maximum
of :
TEMP. RISE ALARM TRIP
class
Power (KVA) < 5000 > 5000 < 5000 > 5000
B 130 °C 125 °C 135 °C 130 °C
F 155 °C 150 °C 160 °C 155 °C
H 175 °C 170 °C 180 °C 175 °C
9
ALTERNATORS
The aluminium plates (E) are pressed against the winding,
d) Stator vibration sensor acting as a heat dissipator and ensure excellent clamping
This chapter concerns the setting of seismic probes. For of these coils.
setting of proximity probes refer to the rotor
Support bars (C) on each pole protect the end windings
The vibration level of the machines is directly linked to the against the centrifugal force.
duty and to the site characteristics.
The revolving field-coil is heated and shrunk onto the shaft.
We propose the following adjustment:
Vibration Alarm (*) = Site Highest Vibration level + 50%
Vibration Trip = Vibration Alarm + 50%
(*) do not pass over the values of the following chart
The machines are engineered to be able to withstand the
vibration level specified by the standard ISO8528-9 and
BS5000-3
Maximum levels for : reciprocating Internal combustion
engines
Nominal speed kVA Generator vibration level 2.2.2 Excitation armature
(rpm) (nominal conditions) The excitation armature is constructed by stacking
magnetic steel laminations. These steel laminations are
Overall Any harmonics held in place by rivets.
(mm/s rms)
(2–1000 Hz) The excitation coil is keyed and heat-shrunk onto the shaft.
1300 à 2199 > 250 < 20 The windings are enamelled copper wires, class "F"
< 0.5 mm ; pp insulation (or "H", depending on the customer's request or
721 à 1299 ≥ 250 < 20 (5 – 8 Hz) size of the machine).
> < 18
1250 2.2.3 Fan (machines: IC 0 A1)
< 9 mm/s ; rm
≤ 720 > < 15 (8 – 200 Hz) The synchronous machine is characterized by a self-
1250 ventilation system. A centrifugal fan is mounted between
the revolving field coil and the front bearing.
< 10 (*)
Air intake is at the rear of the machine and the exhaust on
(*) generator on concrete base the drive end side.
The fan consists of a hub, which is keyed and heat-shrunk
Maximum levels for : Turbines onto the shaft. The flange is made of welded steel,
attached to the hub with hexagonal head-cap screws. The
Turbines Max advised : 4.5 ventilation effect is obtained through, inclined blades. The
(hydraulic ; gaz ; steam) (overall ; mm/s rms)
air is exhausted by centrifugation. The air inlet and outlet
must remains free during operation
2.2 ROTOR
2.2.4 Rotating diode bridge
2.2.1 Revolving field-coil a) General points
The revolving field coil comprises a stack of steel The rectifier bridge, comprising six diodes, is placed at the
laminations, stamped and cut to reproduce the indentation rear of the machine. The rotating bridge is made of glass
of the projecting poles. fibre with a printed circuit to connect the diodes together.
The steel lamination stack-up is terminated at each end This bridge is supplied with alternating current by the
with high-conductivity electrical plates. excitation armature and supplies direct current to the
revolving field-coil. The diodes are protected against over
To enable parallel operation between machines, and in voltage by rotating resistors, or by varistors. These
order to ensure stability, high electrical conductivity bars resistors (or varistors) are mounted in parallel with the
are inserted in holes crossing the poles from one side to revolving field-coil.
the other. These bars are welded with the stack end
laminations in order to obtain a complete cage winding (or
LEBLANC dampening cage).
The winding (B) is placed around the pole (A) and is
impregnated with epoxy resin (class F machine insulation)
or with varnish (class H machine insulation).
The winding is made of insulated flattened copper with
high electrical conductivity.
10
ALTERNATORS
2 c) Rotating rectifier test

Carry out the test using a D.C. source as indicated below.
1 + 3 A diode in good condition should allow the current to flow
only in the anode-to-cathode direction.
Disconnect the diodes before the test.
3 ... 48 volts
- - +
1 - Field 1 2
2 - Rotating resistors
3 - Exciter armature
The inner and outer rings are connected to the revolving

field-coil 1 - Anode
2 - Cathode
1
Diode type Positive Negative
SKR diode housing diode wire
2
SKN diode wire diode housing
When reassembling ensure that the diodes are be

tightened to the correct torque
1 - Outer ring 2.2.5 Balancing

2 - Inner ring The entire rotor has been balanced according to ISO8221
The diode fastening screws must be tightened to the standard in order to obtain a residual imbalance less than :
correct torque. Gen set : Class G2.5
Turbine : Class G1
b) Tightening torque for the rotating diode fastening The balancing is carried out at two levels. The first is that
screws of the fan. It is recommended, when the fan is refitted
(after servicing) to respect the initial indexing.
CAUTION :
THE ROTATING DIODE FASTENING SCREWS MUST The second is that of the shaft end. The shaft end is cold-
BE TIGHTENED USING A TORQUE WRENCH stamped to indicate the type of balancing.
CALIBRATED TO THE RECOMMENDED TORQUE. H : balancing with Half-key carried out as
standard
Diode Tightening torque F : balancing with Full key
N : balancing without key (None)
SKR 100/.. 1.5 m.daN
The coupling must be balanced to fit the generator rotor
SKR 130/.. 1.5 m.daN balancing.
SKN 240/.. 3 m.daN
2.2.6 Rotor vibration sensor
This chapter concerns the setting of proximity probes. For
setting of seismic probes refer to the stator chapter
The vibration level of the machines is directly linked to the
duty and to the site characteristics.
We propose the following adjustment:
Vibration Alarm (*) = 50% of the Bearing shell gap
Vibration Trip = 75% of the Bearing shell gap
11
ALTERNATORS
2.3.3 Maintenance of antifriction bearings

2.3 ANTI FRICTION-BEARINGS
a) General points
2.3.0 Description of antifriction bearings Antifriction bearings or ball bearings do not require special
The bearings are installed at each end of the machine. maintenance.
They can be replaced. They must be lubricated regularly with the same type of
The bearings are protected from external dust by labyrinth grease as used in the factory. For information concerning
seals. the lubrication quantity and interval, refer to Section 1 :
The bearings must be lubricated regularly. The old grease "Characteristics and Performance".
is forced out at the lower part of the bearings by the force CAUTION :
of the new grease being injected.
LUBRICATION MUST BE CARRIED OUT AT LEAST
EVERY 6 MONTHS
2.3.1 Start-up of antifriction bearings
The bearings are pre-lubricated in the factory, but before CAUTION :
they are put into service, it is necessary to complete this IT MUST BE DANGEROUS TO MIX GREASES WHICH
lubrication. HAVE DIFFERENT SOAP BASE. IT IS NECESSARY TO
GET THE GREASE SUPPLIER APPROVAL OR TO
CAUTION CLEAN THE BEARING BEFORE TO PROCEED
UPON START-UP, GREASE THE MACHINE WHILE IT IS
RUNNING SO AS TO FILL ALL THE FREE SPACES IN
THE GREASING DEVICE
NOTE:
Record the temperature of the bearings during the initial After a regreasing the bearing temperature may increase
operating hours. Poor lubrication can cause abnormal of 10 to 20°C
heating. This temporary temperature increase may stay few tens of
hours
If the bearing hisses, lubricate it immediately. Some
bearings may make a clattering noise if they do not
NOTE:
operate at normal temperature. This may occur if the
For re greasing period lower than 2000 hours we
weather is very cold or when the machine is operating
recommend to install a continuous greasing system to limit
under abnormal temperature conditions (start-up phase,
the maintenance operators visit
for example). The bearings will become quieter after
These type of system must be disable during machine stop
having reached their normal operating temperature.
The grease contained in these systems must not be stored
over a period of 1 year
2.3.2 Storage of machine with anti friction bearings
This chapter must be taken in consideration if a machine is b) Lubricant
stopped more than 6 months. Recommended lubricant:
Grease the bearings , machine stopped , inject two time SKF LGWA2
the grease volume used for a standard maintenance. SHELL GADUS S3 V220C (lithium complex base).
Every 6 months turn the the machine shaft line of few SHELL RETINAX LX2 (lithium complex base).
turns. Then inject a standard grease volume CASTROL LMX NLGI2
TOTAL Multis complex EP2
Recommendation for a grease choice ::
Mineral oil or PAO (SHC)
Base (soap ) grade NLGI 2
Lithium complex base
Base oil viscosity at 40°C: 100 to 200 mm2/s
Dye penetration test (DIN 51817) : 2% minimum
Use of grease which do not fit to the recomended figure
(substitution grease) :
Mineral oil or PAO (SHC)
Base (soap ) grade NLGI 2 or NLGI 3
Lithium base
Base oil viscosity at 40°C: 100 to 200 mm2/s
Dye penetration test (DIN 51817) : 2% minimum
CAUTION :
THE USE OF A SUBSTITUTION GREASE CONDUCE TO
REDUCE THE RE GREASING PERIOD OF 30%
12
ALTERNATORS
NOTE:
Lithium and complex lithium soap can be mixed
Lithium complex and calcium lithium soap can be mixed
In case of change of grease brand it is recommended to
proceed to a massive greasing to waste the previous
grease.
c) Cleaning bearings
This note is applicable when the type of grease is
changed.
c) Bearing re-assembly
Dismantle the machine in order to get to the bearing
A bearing can be refitted if it is known to be in perfect
Remove the old grease with a palette knife. condition As far as possible we recommend to use a new
Clean the lubricator and the grease removal tube. bearing
For greater cleaning efficiency, use a brush with solvent. Before refitting a bearing, carefully clean the surface of the
bearing and the other parts of the bearing.
NOTE:
The most widely-used solvent is gasoline : white spirit is Measure the shaft diameter to check it is within the
acceptable. recommended tolerances.
In any cases national environmental and sanitary To install the bearing on the shaft, it is necessary to heat
regulation must be fulfilled. the bearing. The heat source may be an oven or a space
heater (the use of oil baths is strongly discouraged). The
DANGER: use of an induction bearing heater is recommended.
THE PROHIBITED SOLVENTS ARE:
CHLORINATED SOLVENT CAUTION:
(TRICHLORETHYLENE,TRICHLOROETHANE) WHICH NEVER HEAT A BEARING TO MORE THAN 125°C
BECOMES ACID (257°F)
FUEL-OIL (EVAPORATES TOO SLOWLY) Push the bearing up to the shaft shoulder, and check after
GASOLINE CONTAINING LEAD cooling that the inner ring is still in contact with the
BENZINE (TOXIC) shoulder. Lubricate using the recommended grease.
Blow compressed air onto the bearings to evaporate the
excess solvent. 2.3.5 Antifriction bearing protection devices
Fill the bearing with the new grease. As an option, the bearing may be protected from over-
heating by RTD or PTC sensors (customer’s choice)..
Re-assemble the cage and the parts, which have been
For special use in warm surroundings where the
dismantled, filling them with grease.
temperature of the bearings exceeds the authorised limit
Use a grease pump to complete the bearing lubrication (for a bearing known to be in good condition), contact us.
(while machine running)
Bearing; Alarm points and shutdown:
• alarm 90°C (194°F)
2.3.4 Servicing the antifriction bearings • shutdown 95°C (203°F)
a) General points
To improve the machine protection the alarm set point may
CAUTION: be reduced following site effective information:
CLEANLINESS IS IMPERATIVE Alarm temperature (*) = Highest recorded temp + 15°K
(*) do not pass over the values of the previous chart.
b) Removing the bearings
E.g. : At site the common bearing temperature is 60°C . Set
The inner bearing race is mounted, shrunk onto the shaft. the alarm temperature to 75°C instead of 90°C as
The outer bearing race is free, or slightly tightened, on the indicated in the previous chart
hub (depending on the type of bearing). To remove the
bearing from the shaft, it is necessary to use a dedicated
hub-puller to avoid damaging the surface of the shaft.
NOTE:
Heat the bearing during the pulling operation makes the
operation easier and prevent the shaft from scratch.
13
ALTERNATORS
2.3.9 Anti friction bearing installation drawing
Machine type A50
Drive end Non drive end

1 End shield 5 O-Ring
2 End cover 6 Non drive end shield
3 Ball bearing 6226 C3 7 End cover
4 End cover fixing screw 8 Ball bearing 6226 C3
9 Bearing pre load washer
10 End cover fixing screw
14
ALTERNATORS
2.3.9 Anti friction bearing installation drawing (following)
Machine type A52.2; Two bearings
Bearing assembly "Power plant"

Drive end Non Drive end
1 End cover 5 End shield
2 End cover fixing screw 6 End cover fixing screw
3 Ball bearing 6232 MC3 7 End cover
4 End shield 8 Roller bearing NU 1028 MC3
Bearing assembly " Marine "
Drive end Non Drive end
1 9 End shield
2 same as à "power plant" 10 End cover
3 11 End cover fixing screw
4 12 Bearing pre load spring
13 Ball bearing 6226 C3
14 O-Ring
15
ALTERNATORS
Machines A53 and A54 :
Drive end side (2 bearing machine) Non drive end side

1 – End shield 1 – End shield
2 – M12 stud 2 – M12 stud
3 – End cover 3 – End cover
4 - Shaft 4 – Shaft
5 – Ball bearing 6232 MC3 5 – Ball bearing 6328 MC3
6 – Spring
16
ALTERNATORS
Machine type A56 ; Power plant (6 poles and more)

1
2
4 7
5 8 (6248 MC3) 7 1
(NU 232) 8 2
6 4
5
3
Ø440J6
Ø290K6
Tr240x4
Ø240n6
-0,1
-0,1
Ø155 ±0,1
-0,1
Ø158 -0,1
Ø160n5
0
0
0
0
Ø235
Ø180
Ø260
1 – Bearing carrier 3 – Snap ring 5 - Rotating deflector 7 - Inside bearing cover

2 - Outside bearing cover 4 - Fixed deflector 6 - Nut 8 – Anti friction bearing
Machine type A56 ; Power plant (4 poles only)
7 1
2
(NU 232) 8
4
5
6
Ø290K6
O 380 J6
O 180 n5
-0.1
-0.1
0
0
-0,1
Ø155 ±0,1
-0,1
Ø160n5
0
O 220
0
O 175
Ø158
Ø180
1 – Bearing carrier 3 – Snap ring 5 - Rotating deflector 7 - Inside bearing cover

2 - Outside bearing cover 4 - Fixed deflector 6 - Nut 8 – Anti friction bearing
17
ALTERNATORS
c) Operating description of Oil circulation bearing

2.4 SLEEVE BEARINGS Proceed as for the self-lubricated bearings.
Note : For vertical machines refer to the attached specific For special duty of high speed machine or high loaded
bearing notice. bearing it might be necessary to have an oil circulation
Refer to the attached cut view in "chapter 10" for an easier system (external device which ensure the cooling and the
understanding circulation of the oil)
The oil warmed by the bearing losses is externally cooled
2.4.0 Description of horizontal Sleeve bearings and is returned directly to the shell. To obtain efficient
cooling the oil flow must be correct (refer to section 1).
a) Physical description
Rotation of the machine rotor is guided by Sleeve 2.4.1 Electrical insulation of Sleeve bearings
bearings.
The bearing housing is constructed in two ribbed parts a) Illustration diagram of the insulating film
providing considerable heat extraction potential. Following the used technology shaft circulating current
may occurs. When necessary, ACEO insulates the Non
The sleeve bearing comprises two half-shells with an Drive End bearing to avoid shaft-circulating current.
external spherical shape. This allows self-alignment. The
guiding surfaces of the sleeve bearing are covered with tin- An insulating film is applied to the bearing housing
based anti-friction metal. spherical seat.
The spherical seat of the housing of the electrically
insulated bearings is covered with an insulating coating.
The positioning pin of the sleeve bearing in the housing is
also insulated with an insulating bush.
The lubrication ring, mounted free on the shaft, is made of
brass. In order to simplify dismantling, the ring is cut in two
parts, assembled using screws.
A guide for the lubrication ring (synthetic materials) is
attached to the upper bearing half-shell (for marine
applications only).
1 – Electrical insulation
The floating labyrinth seals are cut in two parts, held
together by an expandable ring. These seals are inserted CAUTION:
in a support. A seal-positioning pin rests in the support to WHEN INSULATED BEARING IS USED THE
block it during rotation. ACCESSORIES IN CONTACT WITH THE SHELL MUST
The upper part of the housing is closed by means of a BE ELECTRICALLY INSULATED (TEMPERATURE
glass plug allowing observation of the rotation of the SENSOR …)
lubrication ring. A threaded metal plug allows the bearing
to be filled with oil.
The lower housing may be equipped with an oil-level sight
indicator, a thermometer and a temperature sensor.
b) Operating description of Self-lubricating bearing

Upon stopping, the shaft rests on the lower bearing; there
is metal-to-metal contact.
During the start-up phase, the shaft rubs against the anti-
friction metal of the bearing. Oil lubrication is used.
After having reached its transition speed, the shaft creates
its oil film. At this point there is no further contact between
the shaft and bearing.
CAUTION:
PROLONGED OPERATION AT EXTREMELY SLOW
ROTATION SPEEDS (SEVERAL rpm) WITHOUT
LUBRICATION COULD SERIOUSLY DAMAGE THE
SERVICE LIFE OF THE BEARING.
18
ALTERNATORS
b) Insulation check c) Long term storage

Single bearing machine: When a sleeve bearing machine has to be stopped for
Maintain the rotor at the drive end side to insulate it from more than one year:
the earth (disconnect the coupling if not done). Measure Drain the bearing. Place a "Silicagel" gag inside the
the insulating resistance between the shaft and the bearing oil sump (it is necessary to open the bearing
ground. The insulation should be better than 0.1 MΩ. housing to proceed)
measured under 500 V DC
Place an adhesive strip along the parting lines of the
housing.
1 Pour the recommended protecting agent through the oil
filling hole of the bearing (around 50 cc). Turn the shaft
4 2 several times in order to spread the product evenly
throughout the bearing.
3
CAUTION:
5 A VISIT OF THE BEARING (research of corrosion
marks) MUST BE DONE AT LEAST ONCE PER YEAR
CAUTION:
1 - Bearing shell
2- Insulating film BEFORE START UP IT WILL BE NECESSARY TO
3 - Bearing housing REMOVE THE "SILICAGEL" BAG AND TAPES
4 - Rotor
5 - Insulating wedging
2.4.3 Oil circulation installation
Double bearing machine: Refer to chapter 2.6
Maintain the rotor at the drive end side to insulate it from
the earth (disconnects the coupling; Dismount the drive
end bearing if not done). Measure the insulating resistance 2.4.4 Start-up of Sleeve bearings
between the shaft and the ground. The insulation should
a) General check before start up
be better than 0.1 MΩ. measured under 500 V DC
To identify your bearing characteristics refer to section 1
Installed shell accessories (e.g: RTD) must fit 0.1 MΩ.
measured under 500 V DC This verification must be carried out upon the first start-up,
during periodic inspection of the bearing, or as soon as
any part of the bearing alignment is changed (coupling ...).
2.4.2 Storage of Sleeve bearings machine
After a long shutdown period, proceed following the used
a) General points storage procedure (refer to chapter 2.4.2)
CAUTION: Check that the shaft has not corroded (onto journal
FOR MINERAL OIL WE RECOMMEND THE USE OF surface; thrust faces and seals surfaces)
TECTYL PRODUCTS FROM "VALVOLINE GmbH" SUCH Fill the bearing oil cavities with oil.
AS TYPE "511 M"
FOR SYNTHETIC OIL WE RECOMMEND THE USE OF CAUTION:
"JELT 003400" SPRAY FROM "ITW SPRAYTEC" THE BEARINGS ARE DELIVERED WITHOUT OIL
NOTE : Clean the external parts of the bearing. Dust and dirt
It is possible to start the machine up without removing the impede the radiation of the heat
recommended protection agent. Check if the temperature monitoring equipment works.
b) Short term storage

When a sleeve bearing machine has to be stopped for
more than one month and less than one year:
Do not drain the bearing
Pour the recommended protecting agent through the oil
filling hole of the bearing (around 50 cc). Turn the shaft
several times in order to spread the product evenly
throughout the bearing.
19
ALTERNATORS
b) Self-lubricating bearings start up data d) Oil circulation bearing with non accurate oil flow
To identify your bearing characteristics refer to section 1 (+0% ; -40%)
Fill the bearing with the recommended oil. The oil must be To identify your bearing characteristics refer to section 1
new, absolutely free of any traces of dust or water. This chapter typically applies for standard bearings (as for
bearing types E..Z.K ; E..Z.Q).
The oil level limits are as follows:
minimum oil level: bottom of the oil sight glass The oil circulating bearings (without Leroy Somer
maximum oil level: 2/3 the top of the oil sight glass lubricating system) are delivered with:
a breather
NOTE: It is recommended to filter the oil before filling the an oil inlet flow regulating system.
bearing. The "oil flow regulating system" consists of :
an adjustable pressure reducing valve "A"
CAUTION: a diaphragm.
NOT ENOUGH LUBRICANT LEADS TO TEMPERATURE
RISES AND THUS TO DAMAGE TO THE BEARING. NOTE: The breather can be removed if it is proved that the
TOO MUCH LUBRICANT LEADS TO LEAKAGES. bearing casing is in depressure regarding the atmosphere.
Fit a plug tin place of the breather
Retighten the split line and flange screws (12) by using the
following torque values: The oil flow adjustment does not request high accuracy.
Do not feed the bearing with an oil flow higher than this
Bearing Size 14 18 22 28 one indicated in section 1.
Torque [Nm] 170 330 570 1150 Ensure that the complete oil supply and return lines have
(lightly oiled) been rinsed as instructed in the chapter.2.4.3
Ensure that the installation instructions have been followed
Check the firm position of the top sight glass (5). (refer to chapter.2.4.3 ) such as filtering unit, return line
Check the firm position of the oil sight glass (23). properly inclined etc.
If a temperature sensor or thermometer is used check they Proceed as for the self-lubricated bearings and then
are correctly fixed. start the oil supply system (pump etc.).
Retighten all screw plugs in the connection holes (4), (22), To adjust the oil flow as recommended in section 1:
Machine stopped, adjust the pressure reducing valve "A" to
(24) (27) by using the necessary torque values:
get the bearing oil level at the middle of the glass. And
Plugs threads G 3/8 G 1/2 G 3/4 G1 then run the generator
Machine running and oil at the operating temperature the
Torque [Nm] 30 40 60 110
oil sight glass level should be within 1/3 and ½ of the
glass. If necessary readjust the pressure reducing valve
"A"
Plugs threads G 1 1/4 G 1 1/2 G2 G 2 1/2
Torque [Nm] 160 230 320 500
Check the operation of the temperature monitoring
equipment. A
During the start-up period, check the temperature of the
bearings. The temperature should stay below 95°C an d
then drop down to the temperature normally recommended
(refer to the technical characteristics for Sleeve bearings in
Section 1.)
In case of oil oozing retighten the bearing fixing screws
and the plugs to the recommended torque.
During generator operation the oil level in the bearing must
c) Water cooled bearing (type EFW..) start up data comply with the indications in Chapter 2.4.5.
To identify your bearing characteristics refer to section 1
Proceed as for the self-lubricated bearings and
check the water flow of the cooler. (refer to the data
contained in section 1)
Water has to be filtered as per chapter 2.7.5
20
ALTERNATORS
e) Oil circulation bearing with accurate oil flow

2.4.5 Maintenance of Sleeve bearings
(+5% ; -10%)
To identify your bearing characteristics refer to section 1 a) Verification of oil-level
This chapter typically applies for bearings engineered for Check the oil level at regular intervals.
heavy thrust (tilting pads as for bearing types E..Z.A). The oil level limits are as follows:
minimum oil level: bottom of the oil sight glass
CAUTION:
maximum oil level: 2/3 the top of the oil sight glass
THE OIL FLOW MUST BE CARREFULLY ADJUSTED TO
THE REQUESTED VALUE
Maximum admissible oil level
The oil circulating bearings are delivered with: Optimum top oil level
a breather Optimum bottom oil level
an oil inlet flow regulating system. 2/3
1/2 1/3
The "oil inlet regulating system" consists of : Minimum admissible oil level
an adjustable pressure reducing valve "A" b) Temperature verification
a diaphragm.
Check the bearing temperature and record it. A bearing
NOTE: The breather can be removed if it is proved that the temperature, which suddenly varies without any obvious
bearing casing is in depressure regarding the atmosphere reason (change of ambient temperature etc.), indicates
abnormal operation. It is then necessary to inspect the
Ensure that the complete oil supply and return lines have bearing.
been rinsed as instructed in the chapter.2.4.3
c) Oil draining
Ensure that the installation instructions have been followed
(refer to chapter.2.4.3) such as filtering unit, return line NOTE:
properly inclined etc. Risk of pollution! Please observe the instructions for the
Proceed as for the self-lubricated bearings and then use of the lubricating oil. The manufacturer can provide
start the oil supply system (pump etc.). The oil flow must information on waste oil disposal
be strictly adjusted within the requested value using a flow
It is recommended to drain the oil at intervals of
meter. Run the generator.
8000 hours of operation in dirty environment (eg :
Machine running and oil at the operating temperature the gen set application)
oil sight glass level should be within 1/3 and 2/3 of the 16000 hours of operation in clean environment (eg :
glass. If the level reach the top of the oil sight glass hydro power plant)
investigate for the oil return line design.
A yearly inspection of the oil sump is recommended. Have
f) Inspection of Sleeve bearings at the end of start-up a special attention to water contamination.
Supervise the bearing during the trial run ( 5-10 operating It is possible to decide the oil change only after making an
hours ). analysis and not at fixed period. In such practice the oil
analysis report must fulfill pollution recommendation of
Pay special attention to:
chapter "2.4.10-e":
- oil level
- bearing temperature Shut down the installation and secured it against
- sliding noises of the shaft seals unintended operation.
- tightness of the sump plugs Take all necessary measures to collect all of the lubricating
- tightness of the bearing accessories oil.
- occurrence of vibrations.
Release the lubricating oil while it is still warm. Impurities
CAUTION : and residues will thus be removed.
IF THE BEARING TEMPERATURE EXCEEDS THE Unscrew the oil drain plug (27). Release the lubricating oil
CALCULATED VALUE OF 15 k STOP THE MACHINE and collect it.
IMMEDIATELY. INSPECT THE BEARING AND
DETERMINE THE CAUSES. NOTE:
If the lubricating oil contains unusual residues or is visibly
In case of oil oozing retighten the bearing fixing screws changed, eliminate the causes. If necessary, carry out an
and plugs to the recommended torque
inspection.
Tighten the oil drain plug (27) using the following torque
values:
Bearing size 14 18 22 28
Torque [Nm] 30 40 60 60
Remove the screw plugs from the oil filler hole (4).
21
ALTERNATORS
NOTE: Field pressure measure :
Make sure that no impurities get into the bearing.
Using a transparent tube as water column manometer.
Use a lubricant with the viscosity indicated on the bearing
type plate. Fill the lubricant through the oil filler hole (4) up Connect a flexible transparent tube to the upper part of the
bearing. Connect a pressure tap corresponding to the
to the middle point of the oil sight glass (23).
flexible tube used.
The oil level limits are as follows:
Install the pressure tap in place of the filling plug located
minimum oil level: bottom of the oil sight glass on the top of the bearing housing.
maximum oil level: 2/3 the top of the oil sight glass
Partially fill the pipe with water.
NOTE:
Insufficient lubricant leads to temperature rises and thus to NOTE:
Be careful not to cause water to enter the bearing
damage to the bearing.
Too much lubricant leads to leakage. In the case of Measure the pressure (or depression) in millimeters of
bearings lubricated by a loose oil ring, too much lubricant water column.
could break the oil ring, thus leading to damage to the NOTE:
bearing. Given the low pressures measured, to make the reading
easier it is advised to incline the water column manometer
Tighten the screw plug into the oil filler hole (4) using the
by 5.7° (diagram below). A reading amplification of "10" is
following torque values:
thus obtained.
50 mm
Torque [Nm] 30 40 60 60
5 mm
d) Pressure measurement of a Sleeve bearing housing
The external environment of the electric machine may
5,7°
cause pressurizing or depressurizing of the Sleeve bearing
and lead to oil leakage. 10 mm 100 mm
Example: The oil return line (of a circulation bearing)
99mm 5,7°
opening directly into a diesel motor lower sump and
allowing the housing back-pressure to return to the
bearing.
Example: A vacuum generated by a coupling located too e) Oil for sleeve bearing
close the Sleeve bearing and acting as a fan. We do not have any special recommendation regarding
The relative depression (or pressure) during operation any mineral oil manufacturer.
must remain less than 5 mm of water column. The relative The used oil must comply with the requested viscosity
pressure is the pressure difference existing between the (refer to Section 1).
bearing oil sump and the bearing outside (measured close
to the seals). For frequent cold starting (lower than -15°C) witho ut oil
sump heater please contact us. A new oil viscosity may be
Pe : external pressure advised.
close to the seal Pi
Use a non-foaming mineral oil, without additives. If an oil
Pi : bearing oil sump containing additives has to be used, make sure that the
pressure supplier confirms the chemical compatibility of the oil and
Pm : machine the lead anti-friction properties.
expansion chamber
(gain access as CAUTION:
indicated by the SYNTHETIC OILS MAY BE USED ONLY IF USED
arrow) LUBRICANT ARE ISSUED FROM THE FOLLOWING
Pe
LIST
∆ (Pe - Pi) < 50Pa
∆ (Pm - Pi) < 50Pa Pm Since the synthetic lubricants are not standardized, no
guarantee can be given regarding their chemical and
Note: 50Pa=5mmWC mechanical behavior. Some synthetic lubricant may
become acid and destroys bearing parts (white metal, oil
ring, sight indicator..) in a short time
If synthetic oil has to be used; during the first 2000 hours
of use the lubricant should be checked at short intervals.
22
ALTERNATORS
Viscosity data (for information) : Few examples of mineral oil:
x y viscosity viscosity Type
ISO (cSt ; 40°C)
850 42
775 40 ARAL VG 32 32 Vitam GF 32
700 38 VG 46 46 Degol CL46
680
625 36 VG 68 68 Degol CL 68
550 34
500
BP VG 32 31,5 Energol CS 32
140 32
450 460
VG 46 46 Energol CS 46
30
VG 68 68 Energol CS 68
400 28
365 26 CHEVRON VG 32 30,1 Mechanism LPS 32
315 320 24 VG 46 43,8 Mechanism LPS 46
280 22 VG 68 61,9 Mechanism LPS 68
240 20
205 220 90 50 ESSO VG 32 30 TERESSO 32
18
175 16
VG 46 43 TERESSO 46
140 150 40 14
VG 68 64 TERESSO 68
115 85 12 MOBIL VG 32 30 D.T.E. Oil Light
100 30
85 10 VG 46 43 D.T.E. Oil Medium
60 68 80
20 8 VG 68 64 D.T.E. Oil Heavy Medium
40 46 6
32 75 10W SHELL VG 32 32 Tellus Oil 32
20 22 4
10 0W & 5W 2 VG 46 46 Tellus Oil 46
VG 68 68 Tellus Oil 68
A B C
x - CST at 40°C
y - CST at 100°C The only synthetic lubricant allowed are those one issued
from the following list
A - ISO (VG)
B - SAE J306c Transmissions viscosité Type
C - SAE J300d motors (cSt ; 40°C)
KLUBER 32 Summit SH 32
44 Summit SH 46
62 Summit SH 68
81 Summit SH 100
MOBIL 31 SHC 624
65 SHC 626
SHELL 32 Madrella Oil AS 32
48 Madrella Oil AS 46
68 Madrella Oil AS 68
f) Oil sump capacity (liters)

Bearing EFxxx 14 18 22 28
Volume (l) 8 13 21 34
23
ALTERNATORS
g) Sealing Compound
2.4.6 Dismantling
Mineral oil.
On split surfaces it is possible to use following compounds a) Tools and equipment
(never dry): The following tools and equipment are necessary:
Loctite 128068 - Allan key set
"Hylomar M ; Marton-Domsel" - Wrenching key set
"Universal-Dichtmasse 200 PU ; Reinz-Dichtungs-gmbh" - Open-jaw spanner set
- Feeler gauges (up 0.05mm)
On split surfaces only (do not use on floating labyrinth
- Caliper gauge
seals) it is possible to use following compounds :
- Emery paper, Sleeve scraper
Terostat-9140 ; Teroson
- Lifting equipment
Blue silicone RTV n°6 ; Loctite
- Permanent sealing compound (refer to chapter 2.4.5)
Blue RTV 6B ; Permatex
- Clean cloth
Hi-Temp RTV FAG 26B ; Permatex
- Oil with the viscosity indicated (see bearing type plate)
NOTE: - Detergents
We do not recommend the use of sealing compound onto - Liquid screw locking compound (e.g. LOCTITE 242)
the floating labyrinth seals. - Liquid sealing compound and Teflon tape.
However for certain leakage type , the use of "Curyl T" may
DANGER
help to solve the encountered issue.
BEFORE TRANSPORTING OR LIFTING CHECK IF THE
EYE BOLTS ARE TIGHT! INSECURE EYE BOLTS
CAUTION
COULD RESULT IN THE BEARING BECOMING LOOSE.
COMPOUND WITH SILICONE BASE CAN POLLUTE
BEFORE MOVING THE BEARING BY THE EYE BOLTS
THE SYNTHETIC OIL BATH. THE USE OF SILICONE
MAKE SURE THAT THE SPLIT LINE SCREWS ARE
BASE COMPOUND CAN BE DONE ONLY AFTER
TIGHTENED, OTHERWISE THE BOTTOM HALF OF THE
CHECKING COMPATIBILITY WITH OIL
BEARING COULD BECOME DETACHED.
MANUFACTURER.
MAKE SURE THAT THE EYE BOLTS ARE NOT EX
POSED TO BENDING STRESS, OTHERWISE THE
BOLTS COULD BREAK.
Follow exactly the instructions for the use of the lifting

equipment.
NOTE:
Make sure that the work place is clean. Contamination and
damage to the bearing, especially of the running surfaces,
have a negative influence on the operating quality and
could lead to premature damage.
Shut down the installation and ensure that any unintended

operation is prevented.
Interrupt the cooling water supply (EFW.. bearing only).
Remove all thermo sensors from the connection holes.
Take all necessary measures to collect the lubricating oil.
Unscrew the oil drain plug (27) and collect the lubricating
oil (refer to chapter 2.4.5.c)
b) Lifting equipment
The following steps are to be observed before using the
lifting equipment:
To transport the complete bearing unit
Check if the split line screws are tight (12):
Check if the eye bolts are tight (6).
Connect the lifting equipment to the eye bolts (6).
24
ALTERNATORS
To transport the top half of the housing f) Removal of the top half of the shell
Check if the eye bolts are tight (6).
Unscrew the split line screws (19) and lift the top half of the
Connect the lifting equipment to the eye bolts (6). shell (11).
To transport the bottom half of the housing
CAUTION:
Screw 2 eye bolts (6) with suitable threads tight into the tap
holes (17) marked with a cross. DO NOT DAMAGE THE THRUST AND RADIAL
RUNNING SURFACES.
g) Dismantling of the loose oil ring
Tap hole M 16 M 20 M 24 M 30
Open both split lines of the loose oil ring (44) by
Connect the lifting equipment to the eye bolts (6). untightening and removing the screws (47). Separate both
To transport the Bearing shells halves of the loose oil ring (44) carefully without using any
tools or other devices.
Screw 2 eye bolts or screw hooks with suitable threads
tight into the tap holes (9):
Tap hole M 8 M 12 M 12 M 16
Connect the lifting equipment to the screw hooks.
c) Dismantling of the shaft seal type 10 (outboard side)

Loosen all screws (55) and turn them off.
Remove simultaneously in axial direction both top half (48)
and bottom half (51) of the seal carrier from the housing.
Shift the top half of the seal (53) a little (about 20 mm ). Tilt
it over carefully until the hook spring (49) unbends.
DANGER:
DURING DISMANTLING OF THE FLOATING
LABYRINTH SEAL HOLD TIGHT THE HOOK SPRING
(38). THIS IS UNDER TENSION AND COULD SPRING
BACK AND LEAD TO INJURY.
Open the hook spring (49) and remove the bottom half of
the seal (52) from the shaft.
d) Dismantling of the shaft seal type 20 (outboard side) Illustration 1 : Opening of the loose oil ring
Untight all seals fixing screw (49) and remove them. To check the geometry of the loose oil ring put it together
Simultaneously remove in axial direction both top and as follows:
bottom (48) ,(52) halves of the rigid labyrinth seal. Press the positioning pin (45) into the holes (46).
- Remove the split line screws (50). Adjust both halves of the loose oil ring till the split lines
- Separate the top half of the rigid labyrinth seal (59) from match each other.
the bottom half (63). Tighten the screws (47).
e) Dismantling of the top half of the housing
Remove the flange screws (8).
Remove the split line screws (12).
Lift the top part of the housing (1) until the top part of the
housing can be moved in axial line over the bearing shell,
without touching it.
25
ALTERNATORS
h) Dismantling the machine side shaft seal

2.4.7 Cleaning and checking
Shift the top half of the seal (53) a little (about 20 mm). Tilt
it over carefully until the hook spring (49) unbends. a) Cleaning
DANGER: CAUTION:
DURING DISMANTLING OF THE FLOATING USE ONLY NON-AGGRESSIVE DETERGENTS SUCH
LABYRINTH SEAL HOLD TIGHT THE HOOK SPRING AS FOR INSTANCE
(38). THIS IS UNDER TENSION AND COULD SPRING · VALVOLINE 150
BACK AND LEAD TO INJURY. · ALKALINE CLEANING COMPOUNDS (PH-VALUE 6 TO
9, SHORT REACTION TIME).
Open the hook spring (49) and turn the bottom half of the
seal (52) in the opposite direction to the anti-rotation pin DANGER:
out of the integrated seal groove of the bottom half of the PLEASE OBSERVE THE INSTRUCTIONS FOR THE USE
housing.
OF THE DETERGENTS.
i) Removal of the bottom half of the shell
CAUTION:
CAUTION: NEVER USE CLEANING WOOL OR CLOTH. RESIDUES
MAKE SURE THAT ALL BEARINGS MOUNTED ON A OF SUCH MATERIALS LEFT IN THE BEARING COULD
SHAFT LINE ARE OPENED. LOOSEN THE SPLIT LINE LEAD TO EXCESSIVE TEMPERATURES.
SCREWS OF THE HOUSINGS.
Clean the following parts thoroughly :
CAUTION: top half of the housing (1)
THE LIFTING EQUIPMENT SHOULD NOT COME IN bottom half of the housing (21)
TOUCH WITH THE SEAL AND RUNNING SURFACES top half of the shell (11)
bottom half of the shell (13)
OF THE SHAFT.
sealing surfaces of the top half (48) and bottom half (51)
Lift the shaft up to the point where shaft and bottom half of of the seal carrier or of the rigid labyrinth seal
the shell (13) do not touch each other any more. Protect loose oil ring (44).
the shaft against unintended movement. Water cooler cleaning (bearing type EFW.. only)
Turn the bottom half of the shell (13) out of the bottom half Check the condition of the oil cooler (26).
of the housing (21) and remove it from the shaft. In case the oil cooler (26) is encrusted with oil sludge:
j) Dismantling of the machine seal Dismantle the oil cooler. Remove the encrustation by using
Usually it is not necessary to dismantle the machine seal for instance a wire brush.
(10) if maintenance works are carried out. Install the oil cooler (26) into the bearing.
If due to certain reasons the split machine seal must be
dismantled please observe that this operation can be
carried out only from the inner part of the machine. Loosen
the split line screws of the machine seal and remove the
flange screws (7).
Non-split machine seals can be dismantled only after
dismantling the machine shield or the shaft completely.
In the case the machine seal is equipped with a hamp
packing, some visible changes can be noticed, such as :
tallow excess, black color of the seal due to temperature
development. Even in such cases it is not necessary to
renew the hamp packing. Color changes will appear with a
new hamp packing too, until the seal clearance adjusts
during operation.
26
ALTERNATORS
b) Wear checking
2.4.8 Assembly of the Bearing
Carry out a visual check of the wear condition of all bearing
parts. The following graph provides information on the CAUTION:
parts that must be replaced in case of wear. The right REMOVE ALL IMPURITIES OR OTHER OBJECTS SUCH
evaluation of the wear condition, especially of the running AS SCREWS, NUTS, ETC. FROM INSIDE THE
surfaces of the bearing shell, implies a lot of experience. If BEARING. IF LEFT INSIDE THEY COULD LEAD TO
in doubt, replace the worn part with new ones. DAMAGE OF THE BEARING. COVER UP THE OPENED
Part Wear condition Maintenance proceedings BEARING DURING BREAKS.
Shell Scoring Bearing temperature before
inspection: CAUTION:
· not increased no new CARRY OUT ALL ASSEMBLY OPERATIONS WITHOUT
shells MAKING USE OF FORCE.
· increased new shells
White metal New shell CAUTION:
lining damaged USE A LIQUID SCREW LOCKING COMPOUND (E.G.
LOCTITE 242) FOR ALL HOUSING, SPLIT LINE AND
Bow wave ridges New shells
FLANGE SCREWS.
Shaft Baffles broken or New shaft seal
seal damaged a) Fitting in the bottom half of the shell
Loose Geometrical form New loose oil ring Apply some lubricant on the spherical seating (14) in the
oil ring (roundness, bottom half of the housing (21) and on the running
flatness ) visibly surfaces of the shaft. Use the same type of lubricant as
changed indicated for bearing operation ( see type plate ).
Place the bottom half of the shell (13) on the running
surface of the shaft. Turn the bottom half of the shell (13)
c) Insulation checking (only for insulated bearing) into the bottom half of the housing (21) with the split line
Check the insulating layer of the spherical seating (14) of surfaces of both halves in true alignment.
the top half (1) and bottom half (21) of the housing. In case In case the bottom half of the shell does not turn in easily,
of damage contact Leroy Somer; département ACEO check the position of the shaft and the alignment of the
factory. bearing housing
CAUTION:
(ONLY FOR BEARINGS EF..K)
THESE OPERATIONS SHOULD BE CARRIED OUT
MOST CAREFULLY. THE THRUST PARTS OF THE
BOTTOM SHELL SHOULD NOT BE DAMAGED.
Lower down the shaft till it sits on the bottom half of the
shell (13).
b) Assembly of the shaft seal machine-side

The machine-side shaft seal is standard-wise a floating
labyrinth seal. The integrated seal groove is in the top and
bottom halves of the housing.
DANGER:
DURING ASSEMBLY HOLD THE HOOK SPRING ENDS
SECURELY TO AVOID THEM SUDDENLY RELEASING
AND CAUSING POSSIBLE INJURY!
Check the movement of the floating labyrinth seal on the

shaft in the seal area outside the housing:
Put the hook spring (49) around the shaft and hook both
ends into each other.
Put both halves of the seal (52), (53) in their place on the
shaft.
Put the hook spring (49) into the spring groove (50).
Turn the floating labyrinth seal on the shaft.
27
ALTERNATORS
Remove the rest of the sealing compound.
CAUTION:
THE FLOATING LABYRINTH SEAL SHOULD TURN Push the spring hook into the integrated seal groove
EASILY ON THE SHAFT. A JAMMED SEAL COULD between the bottom half of the housing and the seal until
LEAD TO OVERHEATING DURING OPERATION AND both ends jut out from the split line.
EVEN TO SHAFT WEAR. Place the top half of the seal with the cam facing the inside
of the bearing on the bottom half of the seal.
If the floating labyrinth seal jams, dismantle it from the
shaft. Remove the worn parts of the seal carefully, by Stretch the hook spring until both ends can be hooked.
using emery paper or a Sleeve scraper.
c) Installation of the loose oil ring
Dismantle the floating labyrinth seal. Open both split lines of the loose oil ring (44) by
untightening and removing the screws (47). Separate both
NOTE: halves of the loose oil ring (44) carefully without using any
We do not recommend the use of sealing compound onto tools or other devices.
the floating labyrinth seals.
However for certain leakage type , the use of "Curyl T" may
help to solve the encountered issue.
Apply sealing compound on the guide surfaces of the

integrated seal groove in the bottom half of the housing.
Illustration 2: Coating of sealing compound on the

integrated seal groove
Apply a uniform layer of sealing compound on the seal
surfaces and on the split line surfaces of both halves of the
seal (52), (53).
Illustration 4 : Opening of the loose oil ring

Place both halves of the loose oil ring into the shell groove
(13) encircling the shaft. Press the positioning pin (45) of
each split line into the corresponding hole (46).
Illustration 3 : Coating of sealing compound on the floating

labyrinth seal
Place the bottom half of the seal (52) with the labyrinths
onto the shaft.
The oil return holes at the bearing side must be opened.
Turn the seal in the opposite direction to the anti-rotation
pin into the groove of the housing until the split lines of the
bottom half of the housing and the bottom half of the seal
match each other.
28
ALTERNATORS
Adjust both halves of the loose oil ring until the split lines
e) Closing of the bearing
match each other.
Check the true alignment of the shell (11), (13) and bottom
half (21) of the housing.
The positioning pin (3) in the top half of the housing fits in
the corresponding positioning pin hole (2). The bearing
shell is thus placed into its right position.
Check if the engraved numbers (20) on the top and bottom
halves of the housing correspond.
Clean the split line surfaces of the top and bottom halves
(1), (21) of the housing.
Apply sealing compound over the whole surface of the split
line of the bottom half (21) of the housing.
Illustration 5 : Installation of the loose oil ring
Place the top half of the housing carefully into the machine
Tighten the screws (47) by using the following torque shield, without touching the seals or the bearing shell.
values:
Torque [Nm] 1,4 2,7 2,7 2,7
d) Fitting in the top half of the shell

Apply some lubricant on the running surfaces of the shaft.
Use the same type of lubricant as indicated for bearing
operation (see type plate).
Check if the engraved numbers (15) on the bottom and top
halves of the shell correspond.
Place the top half of the shell (11) on the shaft; both
engraved numbers (15) should be on the same side.
CAUTION :
AN INCORRECTLY PLACED SHELL COULD JAM THE
SHAFT THUS LEADING TO THE DAMAGE OF BOTH
SHAFT AND BEARING.
CAUTION : (FOR BEARINGS TYPE EF..K ONLY)

PLACE THE TOP HALF OF THE SHELL CAREFULLY
ON THE SHAFT. THE THRUST PARTS OF THE TOP
HALF OF THE SHELL SHOULD NOT BE DAMAGED.
Tighten up the split line screws (19) by using the following

torque values:
Torque [Nm] 20 69 69 170
Check the split line of the bearing shell by using a feeler
gauge. The split line gap should be less than 0.05 mm. If
the split line is greater than this, dismantle both top and
bottom (11), (13) halves of the shell.
Check the mobility of the loose oil ring (44).
Marine bearing only:
A guide bush in the top half of the shell secures the
function of the loose oil ring.
Check the mobility of the loose oil ring (44) in the guide
bush.
29
ALTERNATORS
Lower the top half of the housing (1) vertically on the
bottom half of the housing (21). Lower the top half of the
housing (1) until the split line of the housing is not visible
any more.
Gently hit the bottom half of the housing (21) with a nylon
hammer, thus ensuring the alignment of the spherical
seating.
Insert the split line screws (12). Tighten them hand-tight.
Insert the flange screws (8). Tighten them using the
following torque values:
Illustration 6 : Application of sealing compound on the
Torque [Nm] 170 330 570 1150 floating labyrinth seal
Tighten the split line screws (12) of the housing crosswise Press the bottom half of the seal (52) against the shaft.
using the same torque values Place the top half of the seal (53) on the shaft and align
both halves of the seal to each other.
f) Assembly of the type 10 Outboard Side Seals Place the hook spring (49) into the spring groove (50) and
stretch until both ends can be hooked.
DANGER: 43 42 1
DURING ASSEMBLY HOLD THE HOOK SPRING ENDS

38 41 21
(49) SECURELY TO AVOID THEM SUDDENLY

RELEASING AND CAUSING POSSIBLE INJURY!
Check the movement of the floating labyrinth seal on the

shaft in the seal area outside the housing.
Place the hook spring (49) around the shaft and hook both
ends into each other.
Locate both halves of the seal (52), (53) in their place on
the shaft.
Locate the hook spring (49) in the spring groove (50).
Turn the floating labyrinth seal on the shaft.
CAUTION:
THE FLOATING LABYRINTH SEAL SHOULD TURN
EASILY ON THE SHAFT. A JAMMED SEAL COULD
LEAD TO OVERHEATING DURING OPERATION AND
EVEN TO SHAFT WEAR.
If the floating labyrinth seal jams, dismantle it from the

shaft. Remove the worn parts of the seal carefully, by Illustration 7 : Assembly of the floating labyrinth seal
using emery paper or a Sleeve scraper. Align the split line of the floating labyrinth seal and the split
line of the seal carrier.
Dismantle the floating labyrinth seal.
Check that both engraved numbers (56)and(58) on top and
NOTE: bottom halves of the seal carrier (48), (51) correspond.
We do not recommend the use of sealing compound onto Clean the following:
the floating labyrinth seals. the seal surfaces of the top (48) and bottom (51) half of the
However for certain leakage type , the use of "Curyl T" may seal parts: carrier (the groove of the floating labyrinth seal,
help to solve the encountered issue. the flange surfaces)
the split line surfaces of the top (48) and bottom (51) half
of the carrier
the flange surfaces of the housing.
Apply a uniform layer of sealing compound on the seal
surfaces and on the split line surfaces of both halves of the
seal (52), (53).
30
ALTERNATORS
Apply a uniform layer of sealing compound on:
the lateral surfaces of the groove at the top (48) and g) Assembly of the type 20 Outboard Side Seals
bottom (51) half of the seal carrier Check if the engraved numbers on the bottom half (63)
the flange surfaces of the top (48) and bottom (51) half of and top half (59) of the rigid labyrinth seal correspond.
the seal carrier Clean the flange surfaces of
the split line surfaces of the bottom half of the seal carrier the top half and bottom half (63) of the rigid labyrinth seal
(51). the split line surfaces of the top half and bottom half (63) of
the rigid labyrinth seal
the flange surfaces of the housing.
Apply a uniform layer of sealing compound on the following
parts:
the flange surfaces of the top (59) and bottom half (63) of
the rigid labyrinth seal
the split lines of the bottom half (63) of the rigid labyrinth
seal.
Illustration 8 : Application of sealing compound on the seal

carrier
Place the top half of the seal carrier (48) on the top half of
the seal (53). Press the bottom half (51) of the seal carrier
against it. Push the shaft seal completely into the housing.
Illustration 10: Application of sealing compound on the rigid

labyrinth seal
Illustration 9 : Assembly of the seal carrier

Align the split lines of the seal carrier and the housing.
Tighten up the screws (55) by using the torque values:
Torque [Nm] 8 20 20 20
31
ALTERNATORS
Place the top half (59) of the rigid labyrinth seal on the
shaft and press slightly the bottom half (63) of the rigid
labyrinth seal from below against it. Lightly push the rigid
labyrinth seal completely into the housing.
Tighten the split line screws (61).
Place in parallel alignment the split line of the rigid
labyrinth seal and the split line of the housing.
CAUTION:
PRESS THE RIGID LABYRINTH SEAL FROM BELOW
AGAINST THE SHAFT
Adjust the rigid labyrinth seal in such a way that the

clearance "f" between the shaft and the rigid labyrinth seal
at both split lines has the same figure. Illustration 1: Assembly of the RD-thrust pads
Place the top half of the shroud ring (39) into the top half of
the shell (6) by inserting the anti-rotation pin (43) into the
location hole (38). Match the split line of the top half of the
shell (6) with the split line of the top half of the shroud ring
(39) in true alignment.
Illustration 11: Alignment of the rigid labyrinth seal

Tighten the screws (60) by using the following torque
values:
Torque [N.m] 8 20 20 20
h) Assembly of the RD-thrust pads ; bearing type E...A

Clean both top and bottom halves of the shroud ring and
all RD-thrust pads..
Check if the parts show any visible damage. Illustration 2: Assembly of the shroud ring
Carry out the assembly of both thrust parts of the top Tighten the screws (40) by using the following torque
(6) and bottom (27) half of the shell according to the values:
following instructions:
An RD-thrust pad on both sides of the top half of the shell
has a bore for the insertion of a thermo sensor ( thrust part Tap hole M5 M6 M8 M10
temperature measurement).
Torque [N.m] 2,7 8 20 40
To mount the RD-thrust pad into the correct position
proceed as follows: Place the bottom half of the shroud ring (41) into the
- Find the position of the location hole (38) on the top half bottom half of the shell (27). Match the corresponding
of the shroud ring (39).Insert the RD-thrust pad (42) with split lines in true alignment. Tighten the screws (40)
the anti-rotation pin (43) into the corresponding thrust pad with the same torque value as valid for the top half of
location hole (37).
the shell (6).
Insert all other RD-thrust pads (42) into the corresponding
Check the mobility of all RD-thrust pads (42).
thrust pad holes (37)
If the RD-thrust pads jam, realign the top (39) and bottom
of the top and bottom half of the shell (6),(27).
half (41) of the shroud ring.
CAUTION
INSUFFICIENT MOBILITY OF THE RD-THRUST PADS
WILL CAUSE DAMAGE OF THE BEARING.
Both top and bottom halves of the shells are prepared

for assembly.
32
ALTERNATORS
c) Thermostat or sensor (optional)

2.4.9 Oil-leakage trouble-shooting
The recorded oil sump temperature must stay below 85°C
A bearing loss more than 4 drops of oil per day can be in normal condition.
considered as a leakage
Below this quantity this phenomenon is named oozing and The shell temperature must stay below 90°C in norma l
is inherent to sleeve bearing technology. An oil oozing condition.
need a periodic cleaning done by the end user without Shell metal ; Alarm points and shutdown:
necessary corrective action • alarm 95°C (203°F)
Oil leakage can occur in the Sleeve bearings if certain • shutdown 100°C (212°F)
measures are not taken. Oil sump ; Alarm points and shutdown:
• alarm 85°C (185°F)
a) Self-lubricating bearing • shutdown 90°C (194°F)
- Is the oil level correct? (see chapter 2.4.5.a )
To improve the bearing protection the temperature set
- Is the Sleeve bearing in decompression? (see chapter points can reduced following the effective site condition
2.4.5.d ). If the depression level is abnormal, add a
protective screen. Alarm temperature (*) = Highest recorded temp + 5°K
- Is the leakage occurring around the parting line? Clean (*)Highest recorded temp: Temperature measured at
the parting lines carefully with a solvent. Apply a sealing the site in the worst temperature
compound (refer to chapter 2.4.5) upon reassembly (see
chapter 2.4.6) Eg: A bearing reach 80°C in the worst site condition
Adjust the alarm set point to 85°C instead of 95°C a s
b) Oil circulation bearing previously recommended.
- All information and instructions concerning the "self- Adjust the trip set point to 90°C instead of 100°C a s
lubricating bearings" apply. previously recommended.
- Is the bearing oil flow correct (for data refer to section 1)? d) Pre lub pump (optional)
To adjust the oil flow refer to chapter 2.4.4 A pump takes up the oil from the bearing oil sump and
-Is the Sleeve bearing under pressure? pours it over the bearing shell.
To measure refer to chapter 2.4.5 . This pressure most This pump ensures bearing lubrication, increasing the
certainly comes from the oil-return circuit. Check the oil- greasing effect during operation at very low speed and
return circuit (refer to chapter 2.4.3 ). The back-pressure start up period
can often be eliminated by inserting a siphon-effect on the
oil-return line (then make sure that the circuit modification Check the electrical connection of the pump motor to be
does not disturb the oil-return flow). sure of the rotation direction (the rotation direction is
indicated on the pump).
2.4.10 Sleeve bearing protection devices The pump has to be run few seconds before the
synchronous machine starting (pre lub effect) and stopped
a) Sight-level glass as soon as the main shaft line pass over200 rpm
A sight-level gauge is placed on each bearing housing (on For application having a long stop period (time over 5
the left or the right). The level control method is described minutes; eg: Steam Turbine, hydro turbine) the pump has
in chapter 2.4.5 a to be run as soon as the speed pass below 200 rpm
b) Oil thermometer (optional) The pump has to be run continuously during barring period
(eg: engine maintenance)
The thermometer gives the oil sump temperature.
The recorded oil sump temperature must stay below 85°C
in normal condition.
33
ALTERNATORS
e) Oil filtering and pollution

Following indication are related to the maximum 2.6 OIL CIRCULATION LUBRICATING UNIT
acceptable oil pollution level and to the oil filtering level
(filter efficiency) which has to be installed to obtain a clean 2.6.0 General points
oil Oil circulating bearing are noticeable by the third digit of
Refer to Section 1 to get data about the used bearing their code. Letters "Z" ; "X" ; "U" indicate the use of an oil
The viscosity change must remains within +/- 10% of a circulating bearing
fresh oil lubricant Example of oil circulating bearing :
Acidity change must remains (TAN) +/- 0.5 mg KOH/g of a EFZLK ; ERXLA …..
fresh oil lubricant For engineering reason (need of cooling, need of
Humidity ratio must remains below 0.05 % lubrication) an external oil supply can be requested.
This paragraph applies to bearings designed for high axial Following the machine engineering the lubricating oil can
thrust (tilting pads technology as used in bearings type come from different sources :
.....A).
• Oil from the drive engine (System with gravity return)
Maximum acceptable pollution:
following ISO 4406 : 17/15/12 • Oil lubricating unit (System with gravity return)
following NAS 1638 classe 7
• Unit heater
Filtering level to ensure :
following ISO 16889 : β 10 ( c ) = 100 (filtering 10µ) 2.6.1 Oil circulation by gravity return
a) General
This paragraph applies to standard bearings with low axial This chapter applies for bearings, which need an oil
thrust , self lub or oil circulation (as types E..Z.K ; E..Z.Q). circulation system
Maximum acceptable pollution: The operating condition (sequences of operation,
following ISO 4406 : 18/16/13 maintenance …) are given by a specific notice attached to
following NAS 1638 class 9 the present one.
Filtering level to ensure (oil circulation bearing):
following ISO 16889 : β 25 ( c ) = 100 (filtering 25µ)
1 7
3 6
4 5
1 – Oil inlet
2 – Oil sight level indicator
3 – Exhaust elbow
4 – Immediate slope
5 – Following ducts
6 – Return oil sump
7 - Breather
Correct oil flow is obtained by regulating the pressure at
the bearing inlet. (item 1)
34
ALTERNATORS
b) Supply line
To avoid excessive difficulties of cleaning, and to allow an
easy ducting, it is necessary to use pipes requested for 200 mm
mini
hydraulic duty
"H" > 200 mm

mini : 300mm
After installation of the oil lines, rinse the entire oil circuit in
order to avoid dirt or impurities entering inside the bearing
and its connections. Rinse with washing oil. It is important 15°
to remove the instrumentation (for example, pressure
60°
gauge, flow-meter ...) during the rinsing operation to avoid mini
any pollution.
NOTE: Min Average slope: 150 mm / m
Never leave the Sleeve bearing on the rinsing circuit, as
insoluble particles could enter the bearing and damage it.
Install a breather as close as possible of the bearing output
The oil circulating bearings are equipped with an oil inlet The breather should be to a minimum of 200 mm above
pressure regulating system (item 1) the highest point of the bearing.
The delivered oil pressure has to be reduced by the The breather line should be linked to the top side of the
bearing system before entering the bearing to get the main oil line
correct oil flow, refer to chapter 2.4.4 for start up). It is imperative to quickly go down after the bearing output:
Install an elbow (minimum 60°) immediately after th e
A filtering unit must be installed on the supply system.
bearing exhaust.(item 3)
Refer to chapter 2.4.10. Pipe with a Minimum slope of 15° (so: a difference of 25
cm for 100cm long) minimum 300 mm high
c) gravity oil return
The difference of level between return oil sump and
CAUTION: bearing exhaust must be strictly higher than "H"=200 mm
REMEMBER THAT THE OIL EXHAUSTED FROM THE The average slope of the return line must be strictly higher
BEARING GOES BACK TO THE TANK ONLY BY than 15 cm per meter of ground line. The average slope is
GRAVITY EFFECT based on the difference of level between bearing exhaust
and return sump oil level.
CAUTION: The oil return line must no be exposed to counter current
NOT TO FOLLOW THESE RULES MAY CAUSE HEAVY air flow (air which should went from the oil return sump and
LEAKS BY BEARING SUMP OVERFLOW. go toward the bearing).
Eg: a return line which should exhaust above the oil level
CAUTION: inside an engine oil sump should receive a crankcase back
ADVISES AND REQUEST DONE IN THIS CHAPTER DO pressure which should have a real negative effect.
NOT ALLOW THE INSTALLATOR TO COMPLETE BY NOTE : The requested oil flow is indicated in section 1
ITS OWN CALCULATIONS NEEDED FOR A CORRECT Oil return line size :
OPERATION OF ITS SYSTEM.
Flange Thread Ø inter Oil flow ; max
Some bearing may have two exhaust. In this case the both (mm) (l/min)
exhaust lies must be connected ISO VG 32 ISO VG 68
Because of the requested engineering rules the return ISO VG46 ISO VG100
ducts frequently have big size. Their manufacturing is DIN DN32 G 1 ¼" 33 7,5 5,5
frequently done by welding. It will be necessary to clean
the welds and to rinse the oil lines before use. DIN DN40 G 1 ½" 40 11 9
DIN DN50 G 2" 50 17 16
DIN DN65 G 2 ½" 66 30 25
DIN DN80 G 3" 80 45 40
35
ALTERNATORS
Connection in "Y" shape:
It is acceptable to join the return lines of two bearings. In 2.6.2 Oil cooling unit Air/Oil exchanger
this case it is necessary to maintain a constant oil speed This system does not apply to high thrust capability
(Pipe section after = sum of the both pipes section) bearings (bearings noticeable by the fifth digit of their
code). Example : cannot be used for a bearing EFZLA
The "cooling unit" is a compact system totally fitted on the
S2 machine, close to the bearing
S1 S1 + S2 The oil is pumped from the bearing sump, passes through
an Air to Oil cooler, and is then routed back to the bearing
shell. A fan ensure the cooling of the unit using the
ambient air
The oil circulates under low pressure
The oil flow is fixed at the factory without any possible
adjustment.
The pump and the fan must run permanently as long as
the synchronous machine will rotate
No specific maintenance is required (except vibration
dampers)
CAUTION:
IN CASE THE SYSTEM INSTALLED WITH VIBRATION
DAMPERS, THE DAMPERS MUST BE PERIODICALLY
CHECKED AND CHANGED EACH FIVE YEARS.
In case of failure of the "cooling unit" the synchronous

machine :
Remains able to operate safely during a certain time (few
minutes)
The machine can be started without the cooling system
In such event, the bearing temperature will slowly increase
permitting the bearing temperature sensors to detect
overheating, trigger the alarm and protect the bearing by
stopping the machine
36
ALTERNATORS
2.6.3 Oil cooling unit Water/Oil exchanger

2.7 COOLER
This system does not apply to high thrust capability
bearings (bearings noticeable by the fifth digit of their
code). Example : cannot be used for a bearing EFZLA 2.7.0 Description of the cooler
The "cooling unit" is a compact system totally fitted on the a) General points
machine, close to the bearing The purpose of the cooler is to remove machine heat
The oil is pumped from the bearing sump, passes through losses (mechanical, ohmic etc). The exchanger is located
an Water to Oil cooler, and is then routed back to the on the top of the machine.
bearing shell. The water flow is ensured by the electrical Normal operation:
machine The internal air goes through the exchanger, transferring
The oil circulates under low pressure the heat and then goes back to the machine.
The oil flow is fixed at the factory without any possible CAUTION:
adjustment. IN CASE THE HOUSING INSTALLED WITH VIBRATION
The pump must run permanently as long as the DAMPERS, THE DAMPERS MUST BE PERIODICALLY
synchronous machine will rotate. The Water flow must be CHECKED AND CHANGED EACH FIVE YEARS.
ensured as far as the pump is operating.
No specific maintenance is required (except vibration CAUTION:
dampers) THE COOLER MUST BE FULLY OPERATIONAL AS
SOON AS THE MACHINE IS ROTATING (EVEN IF THE
CAUTION: MACHINE IS RUN AT NO LOAD !)
IN CASE THE SYSTEM INSTALLED WITH VIBRATION
DAMPERS, THE DAMPERS MUST BE PERIODICALLY b) Description of Air/Air coolers
CHECKED AND CHANGED EACH FIVE YEARS.
The internal air flow is moved by a fan fixed on the
In case of failure of the "cooling unit" the synchronous machine shaft. The internal cooling air circulates through
machine : the machine and through the air-cooler in a closed circuit.
Remains able to operate safely during a certain time (few The External air circulation can be created through natural
minutes) ventilation (machine class IC 6 A1 A1) or through separate
The machine can be started without the cooling system ventilation(machine class IC 6 A1 A6).
In such event, the bearing temperature will slowly increase
permitting the bearing temperature sensors to detect
overheating, trigger the alarm and protect the bearing by 1
stopping the machine. air 3 air
Water has to be filtered as per chapter 2.7.5
air
Water 2
1 - Air to Air cooler

2 - Ambient air
3 - Internal air
The air-cooler comprises a main housing containing the
tubes and an end housing which act as an air guide
Oil
~
37
ALTERNATORS
c) Description Air/Water double tube exchanger d) Description of Air/Water single tube exchanger
The internal air flow is moved by a fan fixed on the The internal air flow is moved by a fan fixed on the
machine shaft. The internal cooling air circulates through machine shaft. The internal cooling air circulates through
the machine and through the air-cooler in a closed circuit. the machine and through the air-cooler in a closed circuit.
The internal air circulation can be created through natural The internal air circulation can be created through natural
ventilation (machine class IC 8 A1 W7) or through ventilation (machine class IC 8 A1 W7) or through
separate ventilation (machine class IC 8 A6 W7). separate ventilation(machine class IC 8 A6 W7).
Eg : machine class IC 8 A1 W7 An exchanger comprises a fin-tube block containing
1 air • a steel frame
air
• a fin-tube block crimped mechanically onto the tubes.
• The • tube bundle is roll-expanded in the end plates
The water distribution in the tubes is provided by two water
air boxes. One water box is equipped with collars for fitting the
inlet and outlet water lines. Neoprene seals provide
watertightness between the water boxes and the end
plates.
1 – Air to Water cooler A 1

The double-tube technique keeps the cooling circuit from
being affected by possible water leakage. The double tube
provides a high safety level. In case of leakage, the water
goes from the inside of the internal tube to the coaxial
B
space between the two tubes. The water is drained axially
to a leakage chamber where it may activate a sensor.
An exchanger comprises a fin-tube block containing :
• a steel frame. 2 3
• a fin-tube block crimped mechanically to the tubes.
1 - Tube with fins
The tube bundle is roll-expanded in the end plates (parts 3 2 - End plate
and 4) 3 - Water bar
The water distribution in the tubes is provided by two A - Air B – Water
removable water boxes (part 5). A water box is equipped
with collars for fitting the inlet and outlet lines. Neoprene
seals ensure watertightness between the water boxes and
the end plates.
A
B 1
2
3 5
6 4
1 - Single internal tube

2 - External tube with internal grooving and with External
fins
3 - Internal plate
4 - External plate
5 - Outside wall of the pressure tank
6 - Flow of water or liquid leaks
A - Air B - Leakage C - Water
38
ALTERNATORS
c) "Emergency" operation without water

2.7.1 Water Cooler operating condition
As an option the machines can be engineered to be able to
a) Water Cooler installation operate in an "Emergency" mode without water flow
Assembly example: Only machines engineered for this operation case can
1 Outlet flange operate without water flow.
2 Inlet flange
3 Water cooler CAUTION :
4 Connecting flange THIS OPERATING CONDITION CORRESPOND TO A
5 Tap POWER DERATED OPERATING MODE
6 Flexible junction
7 Pipe In such case the machine operate in "open drip proof"
8 Draining and de aeration mode (cooling ensured by ambient air, with a protection
9 Water leakage detector level IP23)
The air inlet and outlet flaps located at the non drive end
and drive end side of the machine must be open
(concerned openings are marked by specific labels) before
running the shaft line
2.7.2 Start-up of the water cooler

a) General points
If the cooler has been stocked for more than 6 months,
recheck the correct tightening of the water boxes .The
st
tightening must be done in 4 steps (1 step , tightening at
nd
¼ of the nominal torque ; 2 step , tightening at 1/2 of the
rd
nominal torque ; 3 step , tightening at 3/4 of the nominal
torque ; final step ; tightening at 4/4 of the nominal torque).
The tightening must be done "diagonally" using a torque
wrench
Bolt M10 M12 M16
Water pipes must be connected stress free
Water pipes must be able to expand without restraint Nominal torque [Nm] 46 79 193
CAUTION:
FOR MACHINE SUPPORTING A VIBRATION LEVEL "diagonally" tightening principle :
HIGHER THAN 5 MM/S RMS WE RECOMMEND THE
USE OF HYDRAULIC FLEXIBLE JUNCTION
A pressure limit or must be installed on the system to

protect the complete assembly against abnormal over
pressure
b) "Standard" operation with water Make sure that the safety devices are operating.
CAUTION: Connect the supply and return lines.
WATER SUPPLY MUST BE EFFECTIVE AS SOON AS Fill with water, whilst carefully draining the circuit.
THE GENERATOR IS ROTATING UP TO THE
COMPLETE SHAFT LINE STOP CAUTION: (machine with motorized fan only)
WE RECOMMEND THAT THE FREE OPERATION OF
CAUTION: THE FAN BE CHECKED (NO FRICTION, NO
WATER SUPPLY MUST BE STOPPED AS SOON AS BLOCKING).
THE GENERATOR IS STOPPED TO AVOID IMPORTANT
CONDENSATION INTO THE GENERATOR CAUTION:
BEFORE START-UP, CHECK THE CLEANLINESS OF
THE COOLER FINS.
Start up the installation (if the other sub-assemblies allow

this).
Load the machine (KVA); adjust the water flow-rate to
obtain the rated flow-rate (refer to Section 1).
Check the water tightness of the lines and of the
exchanger.
39
ALTERNATORS
Check that the temperatures comply with the
recommended temperatures. 2.7.4 Servicing the water-cooler
a) Cooler removal
2.7.3 Maintenance of the water-cooler
The cooler unit is slid into its housing. It is possible to
a) General points remove the cooler from the housing without removing the
water boxes. The cooler is fastened to the housing via a
A regular cooler clogging will have the result to a regular series of screws on the housing.
winding temperature increasing
Remove the supply and return pipes.
The cooler cleaning period is mainly function of the water
purity Provide two supports to hold the cooler when it comes out
of its housing.
In case of used of non recirculated water with risk (eg: river
water with algae passing trough the cooler) we recommend Remove the cooler using slings that can be attached to the
a tubes visit after one year of operation. The following visit connecting flanges.
should be forecasted following the observed dust level.
b) Cooler re-assembly
b) Cleaning Carry out the operations of the "Cooler Removal" chapter
Stop the machine. in the reverse order. Be careful to push the cooler
completely into its housing before tightening the fastening
Cut off the power supply by isolating the inlet and outlet
screws of the cooler to the casing.
lines, and drain the water.
Disconnect the leak sensor (option with double-tube
cooler), and make sure that there are no leaks.
Remove the water boxes on each side of the machine. a) Leak detection (float system)
Rinse and brush each water box. A magnet float activates a switch located in the float
guiding rod
NOTE:
Do not use a hard wire brush as this will remove the
protective oxidation layer which has formed on the A
surfaces of the water boxes. Clean each tube with a metal x
scraper. Rinse in soft water. 1
y
Keep the leakage chamber dry (double-tube water-cooler
only) z
Proceed to a gasket change 2
c) Leak detection for a double-tube exchanger
If a leak is detected, it is necessary to ascertain its origin
1 - Guide rod
immediately and repair it.
2 - Magnetic float
Remove the two water boxes, apply a slight positive
A – No potential contacts
pressure in the leakage chamber and thus between the
x - Blue y - Brown z – Black
two tubes (only concerns double-tube coolers).
If a tube is damaged plug it at BOTH ends. Use a tapered b) Water temperature sensor (optional)
plug. The plug should preferably be made of salt-water A temperature sensor may be installed into the water inlet
resistant aluminum bronze or of a synthetic material. flow of the cooler.
Proposal of adjustment of the water inlet sensor :
Alarm temperature (*) = Water site temp max + 5 °K
c) Water filtering
Water filtering is not ensured by Leroy Somer.
Water filtering must be better than 300 µ
40
ALTERNATORS
2.8 AIR FILTERS 2.18 TERMINAL BOX
2.8.0. General 2.18.0 Description

Only use approved filters. Any filter not correctly Use the attached Terminal box drawing
engineered may conduce to air flow restriction and then to The main terminal box of the machine is located on the top
abnormal generator cooling or to dust entering the of the machine.
generator
The neutral and phase wires are connected to the
terminals, one terminal per phase and one terminal per
2.8.1. Cleaning neutral line. See "Terminal Box" diagram.
a) Air filter cleaning period The openings provide access to the terminals.
The cleaning period depends of the site conditions and can The gland plates are made of non-magnetic materials in
change order to avoid circulating currents.
The cleaning of the filter is requested if the record of the The connection of accessories is achieved by terminal
stator winding temperature (using the stator winding strips. Use a 5 mm maximum screwdriver to work on the
sensors) indicates an abnormal increase in temperature. blocking screws. See the "Machine Protection Devices"
diagram.
b) Air filter, cleaning procedure
The filter element (flat or cylindrical) is immersed in a tank If products have to be added in the terminal box (CT’s,
of cold or warm water (temperature less than 50°C). Use VT’s, Shunt ex) refer to chapter.4.4.3
water with detergent added.
Shake the filter gently to ensure that the water flows 2.18.1 Electric panel
through the filter in both directions. a) Compounding panel (if compound regulator)
When the filter is clean, rinse it with clear water. The compounding panel is located in the terminal box
Drain the filter properly (there must be no more formation The three current transformers (TI 01, TI 02, TI 03), fitted
of droplets) in the terminal box on three power supply conductors,
Refit the filter on the machine. supply the compounding panel.
Rectifier bridges (CR 01, CR 02) rectify the alternating
CAUTION: current coming from these three transformers.
DO NOT USE WATER WITH A TEMPERATURE HIGHER
An RC circuit (R 01, C 01) acts as a filter; CR 03 protects
THAN 50°C, DO NOT USE SOLVENTS.
the system from high voltage spikes.
NOTE : R 02 is an assembly of two adjustable resistors (adjusted
Do not clean the filter using compressed air. This at the factory). Refer to the regulator manual.
procedure would reduce filter efficiency. L 01 is an adjustable self-inducting coil comprising three
coils. The different positions of the jumpers are shown on a
plate attached to the self-inducting coil. L 01 is adjusted to
supply excitation with no load. Refer to the regulator
manual.
b) Booster plate ( if shunt + booster regulator)

The booster plate is located in the terminal box.
The three current transformers TI 01, TI 02, TI 03, fitted to
three power supply conductors, supply the booster plate.
Rectifier bridges (CR 01, CR 02) rectify the alternating
current from these three transformers.
An RC circuit (R 01, C 01) acts as a filter. CR 03 protects
the system from high voltage spikes.
R 02 is an assembly of two adjustable resistors (adjusted
in the factory). Refer to the regulator manual, section
"Principle of Excitation-Regulation".
41
ALTERNATORS
2.18.2 Automatic voltage regulator 3. VOLTAGE REGULATOR AND EXTERNAL

When the automatic voltage regulator is located in the AUXILIARIES
terminal box, it is fitted on a separate plate, insulated from
vibration by means of dampening pads. The operation of The regulator instruction manual may be considered as an
the regulator is explained in chapter 3. independent manual, included in the machine instruction
manual.
CAUTION :
THE DAMPENING PADS MUST BE CHECKED
PERIODICALLY AND REPLACED EVERY FIVE YEARS
2.18.3 Electrical contact tightening

Applicable for brass thread
Thread M5 M6 M8 M10 M12 M14 M16
Torque 2.5 4 8 20 35 57 87
[Nm]
2.19 PROTECTION DEVICES
2.19.1 Stator protection devices

See "Stator protection" in chapter 2.1.3.
2.19.2 Bearing protection devices

See "Bearing protection" in chapter 2.3.5 or chapter 2.4.9

See "Cooler safety" in chapter 2.7.5
2.20 NAMEPLATES
2.20.1. Main nameplate

The main nameplate is fitted to the stator. It gives the
manufacturer's electrical characteristics, the type of
machine and its serial number. The serial number is
necessary for any contact with the factory
For machines with anti-friction bearings, the quantity of
grease, the type and frequency of lubrication are
stipulated.
2.20.2. Lubrication nameplate

The machines with Sleeve bearings have a lubrication
plate attached to the bearing, giving:
Oil change frequency; Oil capacity of bearing; Oil viscosity.
The machines with anti-friction bearings have a lubrication
plate fixed on the stator, giving :
Type of bearing; Grease-change frequency; Quantity of
grease.
2.20.3. Rotation direction nameplate

An arrow on the drive end bearing indicates the rotation
direction.
42
ALTERNATORS
4. INSTALLATION
4.1.4 Unpacking and installation
4.1 TRANSPORT AND STORAGE DANGER :

THE FOUR LIFTING HOOKS MUST BE USED TO LIFT
4.1.1 Transport THE MACHINE WITH SLINGS (ONE HOOK AT EACH
During the transport the intermittent shocks level applied to CORNER OF THE MACHINE)
the machines must remains below 30 m/s
2 Rotors of machines with Sleeve bearings and single-
bearing machines, are blocked during transportation so as
Machines equipped with roller bearing must have their to avoid any movement. Withdraw the retaining bars. The
rotor locked during the transport to avoid "false brineling" retaining bar is screwed to the end of the shaft and to the
problem front support.
Machine temperature must remains within the range -20°C
CAUTION :
to +70°C. Stay down to -40°C during few hours is adm itted.
ALL THE LOCKING DEVICES PAINTED RED OR WITH
The machine must be protected against bad weather RED STICKER MUST BE REMOVED.
conditions and condensation.
Machines must not be handled at temperature below -20°C The end of the shaft is protected from corrosion. Clean it
before coupling.
4.1.2 Storage warehouse
4.1.5 Storage measures of a site machine
The machine must be stored in clean and dry premises
which are not subject to abrupt changes in temperature or Before stopping the machine for a long period (several
months), it is essential to take several precautionary
to high humidity (75% maximum)
measures:
The heating resistor must be switched on at all times
Refer to chapter 2.3.2 (anti friction machine) or chapter
Storage at an ambient temperature of +5 to +45° C is 2.4.2 (sleeve bearing machine)
recommended.
The heating resistor must be switched on at all times.
The machine must not be subject to vibrations higher than
For water-coolers, the water flow must be shut off. If the
1mm/s rms
water is not treated and if there is likelihood of freezing, the
exchanger must be drained.
4.1.3 Maritime packing
For an open machine, it is recommended that the air inlet
The synchronous machine is carefully packed in a wooden and outlet be closed.
crate, then hermetically sealed.
Before starting the machine up again, it will be necessary
Standard maritime packing (For long term storage) as, to carry out a start-up inspection.
seaworthy packing with fully watertight sealed film and
dessicant (silicagel bags) according Category 4C of SEI
standard. 4.2 INSTALLATION OF THE MACHINE
Optional maritime packing (In case of extended storage
period), with a special design with double sealing can be 4.2.1 Fitting the coupling (double-bearing machine
used. This packing enable access to the shaft in order to only)
perform the periodic shaft rotation recommended for The coupling must be balanced separately before
assembly on the machine shaft. Refer to the balancing
antifriction bearings (refer to chapter 2.3.2). This packing
instructions in chapter 2.2.5.
provides access to the dessicant for periodic change
(every 18 months) The shrinking of the half coupling onto the electrical
machine shaft end must be choose, by the gen-set
Breaking the hermetic protective film discharges Leroy manufacturer, in such way as it should be removable for
Somer of its long-duration storage guarantee. maintenance (e.g.: bearing change).
43
ALTERNATORS
c) Sleeve bearing shaft elevation

The calculated displacement is given in " section 1"
4.2.2 Fitting the stator
Four plates on the frame enable the unit to be fitted to a Exact Sleeve bearing elevation due to the oil film :
skid. The machine goes from point "1" to point "2".
The fixing bolts must support the forces created by the
static and dynamic loads. -X X
The machine may be positioned by means of 4 dowel pins.

The dowel pins make later realignment easier. (The use of Y Y
pins is optional).
The machine may be aligned through the use of 4 jacking-
screws. These jacking-screws allow the machine to be β
positioned according to the various axes.
Horaire Stop Anti horaire
Clock Wise Counter Clock Wise
4.3 ELECTRIC MACHINE ALIGNMENT
2 2
4.3.1 Alignment general points
1 1
a) General points
The alignment consist to obtain the driving shaft and the Clear : diametrical clearance
driven shaft coaxial when operating at the nominal Oil film : oil film thickness
conditions (machine rotating ; at its operating temperature) β : Attitude angle
The machine must be aligned according to the ACEO
 Clear. 
standard and adhere to the manufacturer's alignment X= − Oil film  . Sin ( β )
standard for the drive machine.  2 
When heating the machine has its shaft line which grow  Clear   Clear 
up. Between stop and rotation the shaft axis location inside Y = −  − Oil film  . Cos ( β )
its bearing is different. The total axis height elevation is  2   2 
composed of the thermal elevation and of the bearing
elevation. d)Anti-friction bearing shaft elevation
Caused by thermal growth of the anti friction bearing.
CAUTION: "2"
THE ALIGNMENT MUST BE DONE TAKING IN
CONSIDERATION THE SHAFT MOVEMENT Y ° 0,01 mm
CORRECTION
The correct locating of the parts must be obtained by

"1"
inserting shims under the machine pads..
The double-bearing machines are mounted with bearings 1 - cold, in rotation, or stopped
(ball or roller) or Sleeve bearings. The axial clearance of 2 - hot, in rotation, or stopped
the bearings (if the machine has Sleeve bearings) must be
distributed as well as possible, taking into account the axial
thermal expansion. The Anti friction-bearing machines with
a positioning bearing (standard machine) do not have axial
play.
The machines are delivered with the rotor mechanically
centered (axially and radially) in relation to the stator.
CAUTION :
THE ALIGNMENT STANDARDS OF MANUFACTURERS
OF DRIVE MACHINES ARE FREQUENTLY MORE
PRECISE THAN THOSE OF THE A.C.E.O
b) Axis height Thermal elevation

∆ H (mm) =λ (°K -1) . H(m) . ∆T(°K)
H(m) = Height of the machine axis
∆T= frame temperature elevation = 30°C
λ = Coefficient of steel elongation = 0.012 °K-1
44
ALTERNATORS
4.3.2 Two bearings machine alignment 4.3.3 Single bearing machine alignment
a) machines without axial end play (standard) a) General points
The alignment must take the tolerances of the coupling The alignment consist also to get the rotor of the
into account. A misalignment, acceptable by the coupling, synchronous machine coaxial to its stator
must not create an excess load on the bearing subsequent
to the axial and radial stresses outside the tolerances of
said bearing.
Shafts alignment limits to follow:
Angular error
0.01 mm
0.08 mm 100 mm
parallelism error
"A" et "B" give the shaft line alignment
"D" et "E" give the alignment of the stator regarding the
To check the alignment, there are different methods: the rotor.
"double concentricity" method is described in the Because of the engineering of the synchronous machine
"alignment procedure" chapter 4.3.4. the only requested adjustment is "C".
For generators type A60 and A62 "E" can be adjusted
b) machines with axial end play (refer to 6.2.1)
The alignment must be performed using the same method
as for a machine having no axial end play. b) Single bearing machine
It is imperative to position the rotor axially in relation to the
CAUTION: stator in order to achieve correct magnetic centering of the
THE ROTOR AXIAL LOCATION MUST BE CHECKED TO rotor in the stator.
AVOID ANY MAGNETIC OFFSET
Single-bearing machines are delivered by the ACEO
factory with the rotor centered mechanically (axially and
CAUTION: radially) in relation to the stator.
THE FAN THRUST OF THE ELECTRICAL MACHINE
MUST BE HELD THROUGH THE COUPLING. L
A “C”
A needle fitted on the drive end side bearing must face a
groove machined on the shaft. If the needle is missing the
L
distance "A" (distance from the groove up to the first
bearing part) is stamped on the shaft enabling checking.
Example for a sleeve bearing machine : B
1
Two half-shells (B parts) mounted on the front flange act
as a front bearing for the transportation and installation.
The outside of the centring half-shells face a groove
machined on the shaft.
"A" The half-shells have "L = L" construction symmetry
The length "A" shown on the diagram is stamped on the
shaft end (allowing alignment in case of absence of item
"B" rings or in case of absence of groove on the shaft)
The length "L" shown on the diagram is stamped on the
shaft end.
The side "C" represents the machined side of the bearing.
Remove the centring upper half-shell (upper "B" part).
Fit the electric machine to the drive system centering.
45
ALTERNATORS
Remove the centering lower half-shell (lower "B" part).
Carry out the alignment by moving the machine assembly 4.3.4 Alignment procedure
by means of lifting-screws mounted on the brackets (see a) Checking "Double concentricity" alignment method
alignment procedure below). Use shims in order to obtain
This method is not sensitive to axial movements.(the
proper alignment.
alignment methods using axial measure may often be
The centering of the rotor in relation to the stator should be perturbed by small axial movement of the rotor)
checked by measuring the concentricity of the shaft in
It is possible to check the alignment with the coupling
relation to the bearing. After having tightened the fastening
installed.
screws completely, the rotor-stator alignment must be
better than 0.05 mm axis-to-axis (that is 0.1 mm reading). Equipment required :
Two rigid brackets. The rigidity of the two brackets is very
Shafts alignment limits (regarding the drive):
important.
Two micrometers
Angular error Implementation :
During the measures, both shafts must turn simultaneously
0.01 mm in the same direction. (For example : the coupling installed
0.02 mm 100 mm with its screws untightened). By turning both shafts
parallelism error simultaneously, the measurement is not affected by the
error resulting from run out of the two shaft ends.
Check the axial positioning of the rotor in relation to the
stator. For this verification, use an upturned half-shell ("B"
part) (use of the symmetry of the "L = L" part) as shim. The C1
outside of the shim ("B" part) must be facing the groove
machined on the shaft to within +/- 1 mm.
12h B
Mount the cover plates by replacing the transportation half-
shells (delivered separate with the machine) to avoid
9h
foreign matter entering in the machine. Make sure the
closing plates are correctly centered in relation to the shaft. A
3h
6h C2
The "C1" and "C2" micrometers are located at an angular

difference of 180°.
More the distance "L" is long better should be the
sensitivity to detect the angular error
The reading should be performed 4 times for the "C1" and
"C2" micrometers : at 12h, 3h, 6h, 9h
It is recommended to record the results and draw the axes
for better evaluation, as explained below. Interpretation of
measurements by means of an example.
Values given in millimeters. The reading is considered
positive (+) when the micrometer stylus is pushed inwards.
46
ALTERNATORS
MEASUREMENTS
+ 1.34
4.4 ELECTRICAL CONNECTIONS
C1 C2
+ 0.90 4.4.0. General points

+ 0.70 The installation must comply with the electrical diagrams.
12h B
Refer to the attached the electrical diagrams.
+ 0.164 Check that all the protection devices are correctly
connected and in good working order.
9h 3h
+ 0.86 A The assembler has the responsibility to mechanically and
+ 1.04
+ 0.102 electrically protect the generator within the best practice
rules and to secure any operation over the defined tender
6h L=400
(respect of capability curve ; overspeed …)
+ 1.00 For low-voltage machines, power supply cables must be
Measurements referring to the vertical plane: connected directly to the machine terminals (without
Considering the vertical plane "C1" : The vertical action adding washers etc)
towards the top of shaft "A" on the micrometer is dominant. For high-voltage machines, power supply cables should be
In the plane "C1" the axis "A" is higher than axis "B” connected to separate terminals or to current transformer
( 0.9 – 0.1 ) / 2 = - 0.05 mm terminals.
In the vertical plane "C2", the vertical action towards the NOTE:
top of shaft "B" on the micrometer is greater. THE GLAND PLATE IS MADE OF NON MAGNETIC
In the plane "C2" the axis "B" is higher than axis "A" MATERIAL.
( 0.134 – 0.102 ) / 2 = 0.16 mm
The respective position of the axes is as follows: CAUTION
DO NOT ADD WASHERS TO THE POWER SUPPLY
C1 CABLE TERMINALS OTHER THAN THOSE USED BY
B THE MANUFACTURER OF THE ELECTRIC MACHINE
A
Check that the lugs are tightened.
0.16
CAUTION
C2
0.05 ALL CURRENT TRANSFORMERS MUST BE
CONNECTED OR SHUNTED
Regarding the vertical plane the angular alignment error is:
( 0.16 + 0.05 ) *100 / 400 = 0.0525 mm/100mm (not CAUTION
acceptable) THE VOLTAGE TRANSFORMER MUST NEVER BE
Measurements referring to the horizontal axis: SHUNTED
In the plane "C1" the axis "B" is further to the right than "A”
( 0.104 – 0.86 ) / 2 = 0.09 mm CAUTION
In the plane "C2" the axis "B" is further to the left than "A” THE INSTALLED POWER CABLES MUST BE FIXED
( 0.70 - 1.64 ) / 2 = - 0.47 mm AND SUPPORTED IN SUCH A WAY AS TO BE ABLE TO
WITHSTAND THE VIBRATION LEVEL REACHED BY
The representation of the shafts is as follows: THE GENERATOR IN OPERATION (refer to Vibration
C1 chapter)
B
The power cables must not stress (push, pull, bend ...) the
A generator terminals
0.47
C2
0.09
Regarding the horizontal plane the angular error is:

( 0.47 + 0.09 ) *100/ 400 = 0.14 mm/100mm (not
acceptable)
In the both planes the parallelism error is:
52 + 9 2 = 0.103mm or 16 2 + 47 2 = 0.496 mm (not
acceptable)
47
ALTERNATORS
b) On request ; NEMA
4.4.1. Phase-sequence
An arrow located on the front bearing indicates the
a) Standard units ; IEC 34-8 direction of rotation.
Except by special request of the customer, the phase- In the terminal box a specific marking plate indicates the
sequence is carried out using the IEC 34-8 standard. An specific generator phase sequence.
arrow located on the front bearing indicates the direction of
rotation.
In the terminal box a specific marking plate indicates the Counter clockwise rotation Clockwise rotation viewed
specific generator phase sequence. viewed from the stator from the stator connection
connection (NEMA) (NEMA)
(Clockwise rotation viewed (Counter clockwise
Clockwise rotation viewed Counter clockwise rotation from the shaft drive end rotation viewed from the
from the shaft drive end viewed from the shaft following IEC) shaft drive end following
drive end IEC)
The phases are marked: The phases are marked: The cables are marked: The cables are marked:
U1, V1, W1. U1, V1, W1. U1, V1, W1. U1, V1, W1.
Viewed from the front of Viewed from the front of The terminals are marked The terminals are marked
the terminal box the the terminal box the : :
terminals are : terminals are : T3, T2, T1 T3, T2, T1
U1, V1, W1 U1, V1, W1
Viewed from the front of Viewed from the front of
The installer connects : The installer connects : the terminal box the the terminal box the
L1 --> U1 L3 --> U1 cables are : cables are :
L2 --> V1 L2 --> V1 U1, V1, W1 U1, V1, W1
L3 --> W1 L1 --> W1 The installer connects : The installer connects :
L1 --> (U1) T3 L3 --> (U1) T3
L2 --> (V1) T2 L2 --> (V1) T2
L3 --> (W1) T1 L1 --> (W1) T1
U2 V2 W2 U2 V2 W2
T6 T5 T4 T6 T5 T4
U1 V1 W1 U1 V1 W1
U1 V1 W1 U1 V1 W1
1
T3 T2 T1 T3 T2 T1
L1 L2 L3 L3 L2 L1
L1 L2 L3 L3 L2 L1
48
ALTERNATORS
4.4.2 Insulating distances 5. START-UP

Products not delivered by ACEO and then installed in the
terminal box must meet the electrical insulating distances.
5.0 START-UP SEQUENCE
This applies to power cables and lugs, and to added
transformers, etc. The generator start up (commissioning) must follow the
following sequences:
Nominal Voltage 500 V 1 KV 2 KV 3 KV
Phase-Phase in 25 30 40 60 5.0.1 Static checks
the air (mm) Machine fixing as per chapter 5.2
Phase-Earth in the 25 30 40 60 Alignment as per chapter 5.2
air (mm) Cooling as per chapter 5.2
Bearing lubrication as per chapter 5.2
Phase-Phase 25 30 40 70
Electrical connections as per chapter 5.1.0 and chapter
Creeping (mm)
5.1.2
Phase-Earth 25 30 40 70
Winding insulation as per chapter 6.3.2
Creeping (mm)
5.0.2 Rotating checks

Nominal Voltage 5 KV 7,5KV 12,5KV 15 KV
a) Rotating checks not excited
Phase-Phase in 120 180 190 190 Run the generator without excitation by steps to verify the
the air (mm) bearings temperature as per chapter 5.2
Phase-Earth in the 90 120 125 125 At the nominal speed (not excited) measure the vibrations.
air (mm) Check that the vibration level is in accordance with the
generator (as per chapter 5.2.1) and duty request.
Phase-Phase 120 180 190 190
Creeping (mm) b) Rotating checks at no load excited
Phase-Earth 120 180 190 190 In AVR manual mode; Voltage adjustment; check the
Creeping (mm) excitation current value (refer to AVR manual and to the
generator test report)
4.4.3 Added products in the terminal box In AVR automatic mode; Voltage adjustments; Voltage
This may apply to site added customer CTs ; VTs etc. range; check the excitation current value (refer to AVR
manual and to the generator test report)
ACEO must be informed if some appliances have to be
installed in the generator terminal box. At the nominal speed (excited) measure the vibrations.
Check that the vibration level is in accordance with the
The products not delivered by ACEO and then installed in generator (as per chapter 5.2.1) and duty request.
the terminal box must meet the electrical insulating
distances. Refer to chapter 4.4.2. c) Generator and site safeties
The installed appliances must be able to withstand Proceed to the site safeties adjustment (over voltage relay,
vibration. over current relay, differential protection; negative
sequence relay...). The setting points are not under our
responsibility.
Check the synchronizer setting following chapter 5.1.3
For any operation at a speed exceeding the nominal range
(generally the main frequency +3%) the generator
excitation must be shut off (refer to the electrical diagram)
d) Rotating checks at full load

Operating In parallel with the mains
Adjust the Power Factor
Load the generator step by step. :
Check the excitation current at 25%of the rated load
Check the excitation current at 100%of the rated load
At the nominal speed (full load) measure the vibrations.
Check that the vibration level is in accordance with the
generator (as per chapter 5.2.1) and duty request.
49
ALTERNATORS
5.0.3 GENERATOR START UP CHECK LIST

TYPE SERIAL N°
Voltage V Frequency Hz Speed rpm
Output Power kVA Power Factor
STATIC CHECKS
Mechanical checks
• Direction of Rotation Clock Wise or Anti-clock Wise
• Mechanical Fixing of the generator ______________________________________________________
• Coupling - Alignment to the engine ______________________________________________________
• Cooling : Coolant flow and level ______________________________________________________
• Air inlet and exhaust free ______________________________________________________
• Bearing lubrication : Sleeve Bearings Lubrication (flow ; level ; oil type) ________________________
or Anti-friction Bearings Greasing
Temperature sensors (correct readings) _______________________________
• Space Heaters ____________________________________________________________________
Type of AVR : 1F 2F 3F
Electrical connections between alternator, AVR and main panel :

• Output power cables connections following phase order ___________________________________________
• Terminal box connections ___________________________________________
• AVR detection voltage ___________________________________________
• Supply power and excitation terminals ___________________________________________
• Network detection (3F only) ___________________________________________
• Command signals (equalisation and synchronisation for 2F and 3F) _________________________________
• Excitation polarity and booster ___________________________________________
• Protective devices : (Bearing oil level fault detectors; Temperature sensors, etc) __________________
• External accessories (e.g.. remote potentiometer) ___________________________________________
ALL CURRENT TRANSFORMERS MUST BE CONNECTED
Windings insulation
• Insulation test of the : Stator Rotor Exciter armature Exciter field
Measured values in MOhms :
All works must be carried out by a qualified and authorized person.

For more information, please refer to the service manual
Tested by : Date & Signature :
50
ALTERNATORS
ROTATING CHECKS
WITH EXCITATION - AT NO LOAD CONDITIONS
• Verification of the bearings temperature °C _________________________
• In manual mode : Voltage adjustment ___________________________________

Excitation current check ___________________________________
• In automatic mode : Voltage Setting (referring to nominal voltage) ________________________

Excitation current check ___________________________________
• Parallel coupling : Adjustment to parallel operation (3F) ________________________
A FAULTY SYNCHRONISING CAN BE THE ORIGIN OF DAMAGES (HIGH MECHANICAL OVER-

TORQUE)
• Maximum acceptable values for synchronisation to the mains :
Maximum frequency shift 0,1 Hz _________________________
Maximum Phase offset 10 ° _________________________
Maximum voltage (P.N.) difference 5% of Un _________________________
Control / Adjustment of the site safeties

• Over-voltage, _________________________________________________________________
• Over-current (by short-circuit on stator in separate excitation mode), _________________________
• Negative sequence relay, _________________________________________________________________
• Over-speed, __________________________________________________________________
• Differential protection (in static conditions), _____________________________________
• Other protective device. __________________________________________________________________
CHECK THAT ALL SAFETY EQUIPMENT OPERATES CORRECTLY
WITH EXCITATION - LOADED
• Voltage stability __________________________________________________________________

• Adjustment of the Power Factor ____________________________________
• Verification of the excitation current versus load from 25% to full load at rated PF. _______________
• Maximum load value kVA PF
• Vibrations measurements in : mm/s RMS. or other unit

At nominal speed measure the vibrations
Drive End H V A
Non Drive End H V A
All works must be carried out by a qualified and authorized person.

For more information, please refer to the service manual
Tested by : Date & Signature :
51
ALTERNATORS
c) Parallel coupling
5.1 ELECTRICAL START-UP INSPECTION CAUTION:
AN IMPROPER COUPLING CAN BE THE ORIGIN OF
5.1.0 General points DAMAGES (HIGH MECHANICAL OVERTORQUE AND
Electrical connections (auxiliaries, safeties and power OVER CURRENT)
connections) must comply with the diagrams provided.
Refer to chapter 4 At the coupling the following values must not be overpass:
Max frequency shift : 0,1 Hz
DANGER:
Max phase offset : 10° (electrical angle)
CHECK THAT ALL SAFETY EQUIPMENT OPERATES
CORRECTLY. Max voltage (phase - neutral) between machines :
(at phase offset =0) 5 % of the nominal voltage
In case of faulty coupling, of mains fugitive disappearing
5.1.1 Winding Insulation inducing a faulty coupling over what it is acceptable by the
The insulation and the polarization index must be generator, ACEO cannot be considered as responsible of
measured on start up and then each year the damages.
To measure the insulation refer to the chapter.6.3.2
5.2 MECHANICAL START-UP INSPECTION

5.1.2 Electrical connections
The phases must be connected directly to the machine 5.2.0 General points
links (with no spacers or washers, etc).
Make sure that the lugs are sufficiently tightened. a) Alignment ; fixing ; prime mover
The installation must comply with the manufacturer’s
CAUTION: installation rules for drive machine (alignment, mounting).
ALL CURRENT TRANSFORMERS MUST BE An arrow at the drive end, end shield, indicates the
CONNECTED direction of rotation.
b) Cooling
5.1.3 Parallel operation
The air inlet and exhaust must be unobstructed.
a) Definition of parallel operation The cooling auxiliaries (water circulation in the cooler, etc)
• Between machines must be operating.
Parallel operation is possible if the power ratio between the c) Lubrication
smallest machine and the largest machine is less than or
equal to 10. Lubrication must be carried out :
- anti friction bearings, refer to chapter 2.3
• With the mains - Sleeve bearings, refer to chapter 2.4
The "mains" is defined as a source of power greater than
or equal to ten times the output of the machine with which 5.2.1 Vibrations
it will be coupled. The vibration measurement must be taken on each
b) Possibility of parallel operation bearing in the three directions. The measured levels must
be lower than the specified values indicated in the chapter
Parallel operation, if planned at the outset, does not cause 2.1.3
any problems if several basic rules are followed.
Adjust the sensor as per chapter 2.1.3
53
ALTERNATORS
6. PREVENTIVE MAINTENANCE
6.1 MAINTENANCE SCHEDULE

The purpose of the general maintenance schedule below is to help establish the maintenance schedule particular to the
installation. The suggestions and recommendations are to be followed as closely as possible in order to maintain the machine
efficiency and in order not to reduce the service life of the machine.
The maintenance operations are detailed in the chapters relative to the subjects concerned (Example: bearing, see chapter 2).
LUBRICATION AND PREVENTIVE MAINTENANCE SCHEDULE
Frequency of maintenance
Days Hours Comments
STATOR
Winding temperature 1 Refer to 2.1.3
Bolts tightening 8000 (*1) Refer to 6.2.2
Cleaning air inlet and outlet 1000 Refer to 6.2.3
Insulation 8000 (*1) Refer to 6.3.2
Polarisation index 8000 (*1) Refer to 6.3.2
ROTOR
Insulation 8000 (*1) Refer to 6.3.2
Cleaning diodes 8000 (*1) Refer to 7.4
Diodes tightening 8000 (*1) Refer to 2.2.4
Polarisation index 8000 (*1) Refer to 6.3.2
TERMINAL BOX
Cleaning 8000 (*1)
Regulator assembly 8000 (*1) Applicable if mounted in the terminal box
Bolts tightening 8000 (*1) Refer to 6.2.2
Following technical specification in "Section 1"

SLEEVE BEARINGS
Oil leak 1 Refer to 2.4.9
Oil temperature 1 Refer to 2.4.10
Oil level 1 Refer to 2.4.5
Oil drain 8000/16000 Following environment cleanness; Refer to 2.4.5
Bolts tightening 8000 (*1) Refer to 2.4

ANTI FRICTION BEARINGS
Re greasing Refer to 2.3.3 ; See lub plate; grease at least every 6 months
Bearing temperature 1 Refer to 2.3.5
(*1) : Or once a year
54
ALTERNATORS
LUBRICATION AND PREVENTIVE MAINTENANCE SCHEDULE (following)
Days Hours Comments

COOLER
Leakage level 1 Refer to 2.7.5
Water temperature 1 Refer to 2.7.5
Cleaning Refer to 2.7.3 ; following site condition
8000 Voir 2.6.2 ; 2.6.3 ; 2.7.0.a ; 2.18.2 ;

VIBRATION DAMPERS

FILTERS
Cleaning 1000 Refer to 2.8 & following " Section 1"
FAN-MOTOR
Bearing Re greasing Refer to motor lub plate ; following" Section 1"
8000 (*1) Refer to 2.19 et "Section 1 ; (sensors, , ….)
PROTECTION DEVICES
(*1) : Or once a year
55
ALTERNATORS
Bolt : Steel / Steel

6.2 MECHANICAL MAINTENANCE (greasy thread)
To obtain additional information on the maintenance of Ø nominal Torque Ø nominal Torque
sub-assemblies, refer to the chapters dealing with the sub- (mm) (mN) (mm) (mN)
assemblies concerned.
3 1,0 18 222
4 2,3 20 313
6.2.1 Air gap check
5 4.6 22 430
a) General points 6 7.9 24 540
The direct air gap check is not allways possible because of 8 19.2 27 798
a lack of access. When the air gap can be reached the 10 37.7 30 1083
measure can be fastidious because of paint and resin 12 64.9 33 1467
coating on the checked surfaces 14 103 36 1890
To make the measure more reliable and easy the air gap 16 160
check will be done onto the exciter :
Air gap < 1 mm max offset : 0.1 mm
1 mm ≤ Air gap max offset 10% of air gap
b) Double bearing machine

Verification of the air gap is not necessary. The rotor is
mechanically centered by its construction. Even after
dismantling and reassembling the machine, the rotor will
return to its position without verification of the air gap.
The exciter air gap of generators type A60 and A62 are
site adjustable.
c) Single bearing machine

When the machine is delivered, the rotor is mechanically
centered in the stator (see chapter on alignment). After
dismantling the machine, it will be necessary to center the
rotor in the stator, by using the two half-shells (delivered
with the machine) as explained in the chapter 4.3.3.
If you do not have 1/2 shells, use a dial indicator to check
the concentricity between the shaft (machined surface)
and the front bearing (machined surface).
6.2.2 Bolts tightening

Check the tightening of the sleeve bearing fixing bolts
(refer to chapter 2.4)
Check the tightening of the rotating diodes (refer to chapter
2.2.4)
Check the tightening of the terminal box accessories (refer
to chapter 2.18)
If no torque value is specified into the concerned chapter
the following values can be used
57
ALTERNATORS
b) Identification of ohmmeter polarity

Steel and copper alloy Plugs In many testing procedures, the ohmmeter polarity is
(greasy thread) important (diode test, etc) and must be known. As a
second instrument, you must use a voltmeter in the "direct
Ø nominal Torque Ø nominal Torque
current" position, in order to check the polarity of the
(inches) (mN) (inches) (mN)
ohmmeter connections. Proceed as explained below :
G3/8 30 G1 ¼ 160
G1/2 40 G1 ½ 230
8
G3/4 60 G2 320 0 Volts 10 Ohms 0
G1 110 G2 ½ 500
DC ž
6.2.3 Cleanliness
The whole machine must be kept clean.
CAUTION :
ALL THE CLEANING PERIODS INDICATED IN THIS
MANUAL MAY BE CHANGED (INCREASED OR
DECREASED) ACCORDING TO SITE CONDITIONS
6.3.2 Insulation check of the winding
The air inlet and air outlet surfaces must be maintained
a) General
clean (Louvers can be cleaned as per the filters) refer to
chapter 2.8. The insulation resistance enables the status of the
machine insulating to be verified.
CAUTION :
The following measurements can be taken at any time
DIRT ENTERING THE MACHINE MAY POLLUTE AND
without any damage to machine insulating material.
THUS REDUCE THE ELECTRICAL INSULATION
The insulation check must be done :
The rotating diodes must be keep clean. The rotating Before the start up
diodes cover has to be clean. Refer to chapter 7.4 After a long standstill
As soon as an abnormal operation occurs.
6.3 ELECTRICAL MAINTENANCE If the measurement indicates a poor result we advise
contacting our Service department.
6.3.1 MEASURING INSTRUMENTS To perform the measurement the generator must be
stopped.
a) Instruments used
- AC voltmeter 0-600 Volts If the insulation resistance is less than that required, it is
necessary, to clean and to dry the machine (refer to
- DC voltmeter 0-150 Volts chapter 7.5).
- Ohmmeter 10E-3 to 10 ohms
DANGER :
- Megohmmeter 1 to 100 MOhms / 500 Volts BEFORE ANY WORK THE RULES CONCERNING THE
- AC Ammeter 0- 4500 A SAFETY OF MATERIALS AND PERSONS MUST BE
APPLIED (TOTAL LOCKING OF THE GENERATOR
- DC Ammeter 0-150 A
FUNCTIONS, GROUNDING OF THE PHASES …)
- Frequency meter 0-80 Hz
Low resistance can be measured by means of an b) Armature insulation measure
appropriate ohmmeter or by using a Kelvin or Wheatstone Disconnect the three phases at the generator terminals.
bridge.
CAUTION
NOTE :
ALL ACCESSORIES MUST BE DISCONNECTED (AVR ,
The identification of the equipment polarity may differ from
EMC FILTER ;;;)
one ammeter to another.
REFER TO THE ELECTRICAL DIAGRAM TO IDENTIFY
THE ACCESSORIES TO DISCONNECT
58
ALTERNATORS
The measurement has to be taken between one phase and e) Polarization index
the earth.
The polarization index enables the status of the machine
Machine nominal voltage insulating to be verified and gives an indication of the
pollution of the winding.
Un ≤ 2400 V Un > 2400 V
A poor polarization index may be corrected by a cleaning
Applied test 500 V DC 1000 V DC and drying of the winding
voltage (DC) The following measurements can be taken at any time
without any damage to the machine insulating material.
[3 (U n + 1)] MΩ
The measured value at 25°C must be over
CAUTION
where Un (the nominal voltage) is in Kilovolts. (e.g. : a ALL ACCESSORIES MUST BE DISCONNECTED (AVR ,
generator of 6.6 KV must have an insulation resistance EMC FILTER ;;;)
greater than 22.8 MΩ). REFER TO THE ELECTRICAL DIAGRAM TO IDENTIFY
If the minimum insulation level is not reached, dry the THE ACCESSORIES TO DISCONNECT
windings (refer to chapter 7.5)
NOTE:
c) Field insulation measurement It must be done using a stable DC source.
Disconnect the two ends of the field at the rotating diodes Use a specific polarization index appliance under 500 or
bridge 1000 DC volts (refer to" insulation of the winding" chapter
The measurement should be taken between one end of the for the correct applied voltage)
field winding and the earth.
Open the winding star point
The applied test voltage must be of 500 V DC.
Disconnect AVR cables from the stator terminals
The measured value must be over 20 MΩ.
If the minimum insulation level is not reached, dry the
windings (refer to chapter 7.5)
d) Exciter insulation measurement

CAUTION
ALL ACCESSORIES MUST BE DISCONNECTED (AVR ,
EMC FILTER ;;;)
REFER TO THE ELECTRICAL DIAGRAM TO IDENTIFY
THE ACCESSORIES TO DISCONNECT
To measure the exciter field insulation disconnect the two

ends of the exciter field at the terminals located on the top Apply the requested voltage
of the exciter.
After 1 minute record the Insulating resistance
To measure the exciter armature insulation disconnect the
two ends of the exciter armature at the rotating diodes After 10 minutes record the Insulating resistance
bridge
The measurement should be taken between one end of the
field winding and the earth.
The applied test voltage must be of 500 V DC. The polarization index must be higher than 2.
The measured value must be over 20 MΩ. Proceed for each phase
If the minimum insulation level is reached, dry the windings
(refer to chapter 7.5)
59
ALTERNATORS
7. SERVICING 7.4 CLEANING THE WINDINGS
7.1 GENERAL SERVICING 7.4.0 General points

The cleaning of the winding is an heavy service operation
DANGER : which has to be engaged only if necessary.
BEFORE WORKING ON THE GENERATOR, MAKE
SURE THAT THE START-UP CANNOT BE ACTIVATED The cleaning of the windings become necessary as soon
as the insulation resistance and/or the polarization index
BY ANY MANUAL OR AUTOMATIC SIGNAL
are not satisfactory (refer to chapter 6.3.2)
DANGER:
BEFORE WORKING ON THE MACHINE, MAKE SURE 7.4.1 Coil-cleaning product
THAT YOU HAVE UNDERSTOOD THE OPERATING a) General
PRINCIPLES OF THE SYSTEM. IF NECESSARY, REFER A long term efficient cleaning can only be done in a work
TO THE APPROPRIATE CHAPTERS IN THIS MANUAL. floor if equipped with specialized devices. A site cleaning,
because less efficient, can be considered only for a
CAUTION: transient period.
GIVEN THE POWER FACTOR APPLIED TO THE
MACHINE, A VOLTMETER OR KILOWATT METER CAUTION:
DOES NOT NECESSARILY SHOW THE KVA LOAD OF SOLVENTS, WHICH ARE HIGHLY CHLORINATED AND
THE MACHINE. SUBJECT TO HYDROLYSIS IN DAMP ATMOSPHERES
ARE PROHIBITED. THEY QUICKLY BECOME
ACIDIFIED, PRODUCING CORROSIVE AND
CONDUCTIVE HYDROCHLORIC ACID.
7.2 TROUBLESHOOTING
CAUTION:
DO NOT USE TRICHLORETHYLENE,
When a defective part is replaced with a spare part, make PERCHLORETHYLENE, OR TRICHLORETHANE
sure that it is in good condition.
Avoid mixtures sold under various trademarks which often
7.2.1 Regulator trouble-shooting procedure contain white spirit (which evaporates too slowly) or
Refer to the enclosed regulator manual. chlorinated products (which are likely to become acidified).
CAUTION:
DO NOT USE ALKALINE PRODUCTS. THEY ARE
7.3 ELECTRICAL TESTS
DIFFICULT TO RINSE AND CAUSE REDUCTION OF
INSULATION RESISTANCE BY FIXING THE HUMIDITY
7.3.1 Stator winding test
See chapter 6.3 b) Cleaning products
Use pure de-greasing and volatile agents which are well-
7.3.2 Rotor winding test defined such as :
See chapter 6.3 Gasoline (without additives)
Toluene (slightly toxic ) ; inflammable
7.3.3 Excitation armature winding test Benzene or benzine (toxic ; inflammable)
See chapter 6.3 Ciclohexaire (non-toxic; inflammable)
Soft water
7.3.4 Excitation field winding test

See chapter 6.3
7.3.5 Rotating diode bridge test

See chapter 2.2
7.3.6 Electric panel test

Use electrical diagrams for assistance.
60
ALTERNATORS
7.4.2 Cleaning the stator, rotor, excitation system and

diodes
7.5 DRYING THE WINDING
a) using specific chemical product 7.5.0 General points
The insulation and the impregnation system are not All electric machines must be stored under dry conditions.
damaged by solvents (see the list of authorized products If a machine is placed in damp surroundings, it must be
above). dried before it is put into service. Units operating
intermittently or placed in areas with high temperature
It is essential to avoid entry of cleaning agents into the variations, are exposed to dampness and must be dried
slots. Apply the product with a brush, sponging frequently very thoroughly if necessary.
in order to avoid accumulation in the housing. Dry the
winding with a dry cloth. Allow the traces to evaporate
7.5.1 Drying method
before reassembling the machine.
a) General points
CAUTION:
During the drying operation measure the winding insulation
AFTER CLEANING THE GENERATOR, DRYING IS and the polarization index each 4 hours.
IMPERATIVE TO RECOVER THE CORRECT WINDING
INSULATION To survey the insulation progress, record the measured
values and plot the obtained progress function of the time.
b) Rinsing using soft water When the insulation value becomes constant, the machine
can be considered as dry.
Hot soft water (less than 80°C) used under pressure (less
than 20 bars) can be used. When the resistance is constant, it may be assumed that
the machine is dry. This operation may take up to 24
CAUTION: hours, depending on the size of the machine and on the
AFTER CLEANING THE GENERATOR, DRYING IS degree of dampness. This may even take up to 72 hours.
IMPERATIVE TO RECOVER THE CORRECT WINDING
INSULATION CAUTION:
TAKE FIRE-PREVENTION MEASURES DURING THE
DRYING OF THE MACHINE.
ALL THE CONNECTIONS MUST BE TIGHTENED.
b) Drying generator stop

The procedure " Drying generator in rotation" should be
preferred to the following one if it is possible to run the
generator at its nominal speed
Several thermometers must be positioned onto the winding
and the temperature must not exceed 75°C (167°F). I f one
of the thermometers exceeds this value, immediately
reduce the heating effect.
Dry by using an external source of heat, for example,
heaters or lamps.
Leave an opening for an exhaust for the damp air.
c) Drying generator in rotation

Disconnect the machine from the mains
Short circuit the machine stator at the machine terminals
Disconnect the Voltage regulator and short-circuit the
booster.
Install an amp meter on the short-circuited winding.
Run the machine at its nominal speed (to air cool the
machine)
Energized the machine (exciter field) using an separate ex
citation source. Use a DC source (batteries ...)
Adjust the excitation current to get the nominal current at
the stator (machine armature).
Warm up during 4 hours, stop and leave it to cool down
(winding temperature < 50°C)
61
ALTERNATORS
Check the winding insulation and the polarization index
If necessary conduce an other drying period...
U1
C
U2
V1 A B
V2
W1
W2
+ -
DC
A - Stator
B - Rotor
C - Exciter
7.6 RE-VARNISHING
CAUTION:
RE VARNISHING MUST ONLY BE CONSIDERED IF
ABSOLUTLY NECESSARY. A RE VARNISHING
OPERATION DONE ON A WINDING STILL DIRTY OR
NOT PERFECTLY DRY MAY CONDUCE TO A
DEFINITIVE LOSS OF INSULATION
62
ALTERNATORS
10. TYPICAL CUT VIEWS
10.1 MACHINE CUT VIEWS
10.1.1 Machine type A52

1 Rotor 10 Polar wheel
2 Bearing (drive end) 11 Balancing disc
3 Fan hub 12 Exciter field
4 Drive end shield 13 Exciter armature
5 Fan 14 Non drive end shield
6 Fan screen 15 Bearing (non drive end)
7 Stator winding 16 Rotating resistances
8 Stator ribs 17 Rotating diodes
9 Stator lamination 18 Diode bridge cover
4 5 6 7 8 9 10 11 12 13 14
15
16
2
17
1
4 5 6 7 8 9 10 11 12 13 14
15
16
2
17
1
63
ALTERNATORS
10.1.2 Machine type A53 ; A54

64
ALTERNATORS
10.1.3 Machine type A56 ; A58

4 5 6 7 8 9 10 11 12 13 14
3 15
2 16
1 17
65
ALTERNATORS
10.2 FLANGED SLEEVE BEARING
10.2.1 Self lubricating bearing

1 Top half of the housing 15 Engraved number - bearing shell
2 Positioning pin hole 16 Recess
3 Positioning pin 17 Tap hole
4 Oil filler hole 18 Screw
5 Top sight glass 19 Split line screw - bearing shell
6 Eye bolt 20 Engraved numbers - bearing housing
7 Screw 21 Bottom half of the housing
8 Screw 22 Connection hole for temperature measurement of the journal
9 Tap hole ( in the top and bottom halves of the shell, up size part
14 ) 23 Oil sight glass
10 Machine seal 24 Connection hole for the oil sump temperature measurement
11 Top half of the shell 25 Out/Inlet cooling water (Type ExW xx)
12 Split line screw - bearing housing 26 Oil cooler ( Type ExW xx)
13 Bottom half of the shell 27 Oil drain plug
14 Spherical seating
66
ALTERNATORS
10.2.2 Oil circulation bearing

1 Top half of the housing 16 Recess
2 Positioning pin hole 17 Tap hole
3 Positioning pin 18 Screw
4 Connection hole for the thrust part oil supply (optional) 19 Split line screw - bearing shell
5 Top sight glass 20 Engraved numbers - bearing housing
6 Eye bolt 21 Bottom half of the housing
7 Screw 22 Connection hole for temperature measurement of the journal
8 Screw part
9 Tap hole ( in the top and bottom halves of the shell, up size 23 Oil inlet connection hole
14 ) 24 Connection hole for the oil sump temperature measurement
10 Machine seal 25 Out/Inlet cooling water (Type ExW xx)
11 Top half of the shell 26 Oil cooler ( Type ExW xx)
12 Split line screw - bearing housing 27 Oil drain plug
13 Bottom half of the shell 28 Metal tabs ( optional for EFZLx )
14 Spherical seating 29 Oil outlet connection hole
15 Engraved number - bearing shell 30 Oil outlet pipe
31 Marking
67

Manual Alternator PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Alternator PDF

Uploaded by

Copyright:

Available Formats

2327 en – 11.

2.3.3 Maintenance of antifriction bearings

1.2 GENERAL DESCRIPTION 2.4 SLEEVE BEARINGS (Plain)

3. VOLTAGE REGULATOR AND EXTERNAL 5. START-UP

7.1 GENERAL SERVICING

7.2 TROUBLE SHOOTING

7.3 ELECTRICAL TESTS

7.4 CLEANING THE WINDINGS

7.5 DRYING THE WINDING

1. GENERAL INFORMATION 1.1.2 Conditions of use

1.2 GENERAL DESCRIPTION

1.2.2 Excitation system

1- Excitation field winding

b) Stator winding temperature sensor

2 c) Rotating rectifier test

The inner and outer rings are connected to the revolving

When reassembling ensure that the diodes are be

1 - Outer ring 2.2.5 Balancing

2.3.3 Maintenance of antifriction bearings

2.3.9 Anti friction bearing installation drawing

Machine type A50

Drive end Non drive end

2.3.9 Anti friction bearing installation drawing (following)

Machine type A52.2; Two bearings

Bearing assembly "Power plant"

2.3.9 Anti friction bearing installation drawing (following)

Machines A53 and A54 :

Drive end side (2 bearing machine) Non drive end side

2.3.9 Anti friction bearing installation drawing (following)

Machine type A56 ; Power plant (6 poles and more)

1 – Bearing carrier 3 – Snap ring 5 - Rotating deflector 7 - Inside bearing cover

Machine type A56 ; Power plant (4 poles only)

1 – Bearing carrier 3 – Snap ring 5 - Rotating deflector 7 - Inside bearing cover

c) Operating description of Oil circulation bearing

b) Operating description of Self-lubricating bearing

b) Insulation check c) Long term storage

b) Short term storage

e) Oil circulation bearing with accurate oil flow

f) Oil sump capacity (liters)

Follow exactly the instructions for the use of the lifting

Shut down the installation and ensure that any unintended

c) Dismantling of the shaft seal type 10 (outboard side)

h) Dismantling the machine side shaft seal

b) Assembly of the shaft seal machine-side

Check the movement of the floating labyrinth seal on the

Apply sealing compound on the guide surfaces of the

Illustration 2: Coating of sealing compound on the

Illustration 4 : Opening of the loose oil ring

Illustration 3 : Coating of sealing compound on the floating

d) Fitting in the top half of the shell

CAUTION : (FOR BEARINGS TYPE EF..K ONLY)

Tighten up the split line screws (19) by using the following

DURING ASSEMBLY HOLD THE HOOK SPRING ENDS

(49) SECURELY TO AVOID THEM SUDDENLY

Check the movement of the floating labyrinth seal on the

If the floating labyrinth seal jams, dismantle it from the

Illustration 8 : Application of sealing compound on the seal

Illustration 10: Application of sealing compound on the rigid

Illustration 9 : Assembly of the seal carrier

Adjust the rigid labyrinth seal in such a way that the

Illustration 11: Alignment of the rigid labyrinth seal

h) Assembly of the RD-thrust pads ; bearing type E...A

Both top and bottom halves of the shells are prepared